Battery Electrode Foil Laser Cutting With Pulsed Heat Control
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Solution Overview
Problem
Metal foils used as electrodes in batteries are prone to deformation or tearing during laser cutting due to inappropriate setting of laser cutting parameters, necessitating a more precise and high-quality cutting method.
Innovation Solution
A metal foil laser cutting method involving intermittent laser pulses with specific energy levels, overlapping ratios, and scanning conditions to ensure precise cutting of metal foils forming battery electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser cutting parameters are set similarly to those used for thicker metal members, then the laser cutting process can be simplified, but the metal foil becomes deformed or torn due to excessive heat input
Solution Approach 1:
The patent applies parameter changes by adjusting laser cutting parameters specifically for metal foil: reducing laser power to 100W or less, setting pulse width to 1ms or less, and controlling scanning speed to 100mm/s or less. These parameter modifications prevent excessive heat input that would cause deformation or tearing, while maintaining a straightforward cutting process
Solution Approach 2:
The patent employs periodic action through pulse laser irradiation with pulse widths of 1ms or less. This intermittent heating approach allows heat to dissipate between pulses, preventing cumulative heat buildup that would deform the thin metal foil, while still achieving effective cutting through repeated thermal cycles
2Productivity
If laser power is increased to cut through metal foil quickly, then productivity improves, but the metal foil deforms or tears due to excessive energy input
Solution Approach 1:
The patent uses periodic pulse laser irradiation with pulse widths of 1ms or less and appropriate pulse frequencies. This allows rapid sequential heating cycles that cut through the foil efficiently while providing cooling intervals between pulses, preventing deformation from continuous high-power exposure
Solution Approach 2:
The patent applies dynamics by implementing real-time control of laser parameters during cutting: adjusting pulse width, power, and scanning speed based on the specific foil thickness and material properties. This dynamic parameter adjustment optimizes cutting speed while preventing excessive heat input that would cause deformation
3Productivity
If pulse frequency is increased to reduce cutting time, then productivity improves, but heat accumulation causes deformation of the metal foil
Solution Approach 1:
The patent optimizes pulse frequency to achieve the right balance between productivity and quality. By controlling the pulse repetition rate, the system accumulates sufficient heat for effective cutting while maintaining intervals that allow heat dissipation, preventing deformation from excessive heat accumulation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high-quality laser cutting of metal foils with reduced deformation and tearing, enabling efficient production of battery electrodes.
Implementation Method 1
a laser cutting process that uses laser light irradiation... emit the laser light onto a certain part to be cut of the workpiece, so as to melt the part with energy of the laser light
Data Source
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AI summary
A metal foil laser cutting method includes, for example, intermittently irradiating a metal foil that forms an electrode of a battery and that serves as a workpiece with a pulse of a laser light of which energy per pulse is 2 [mJ] or more and 100 [mJ] or less and of which rise time is 2 [µs] or shorter to laser cut the workpiece. The pulse may intermittently be emitted at a frequency of 500 [kHz] or less. The metal foil may have a thickness of 500 [µm] or less. The metal foil may have a site covered by a coating and a site not covered by a coating.