Secondary Battery Electrode Tab Notching Without Insulating Layer Melting
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Solution Overview
Problem
The existing methods for manufacturing secondary battery electrodes with insulating layers face issues such as re-fusion, debris formation, poor profile, lifting, and exposure of current collectors due to the melting of insulating layers during the cutting process, which affect the efficiency and quality of the electrodes.
Innovation Solution
A method using a laser with a pulse width of 100 ps to 10^-6 ps for notching the electrode tabs with an insulating layer, which minimizes melting and improves cutting efficiency and quality by cutting the insulating layer and current collector in a laminated state, resulting in a stable and reliable electrode profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser cutting method is used to notch the electrode tab, then the manufacturing efficiency is improved, but the insulating layer melts and causes re-fusion, debris formation, and poor profile quality
Solution Approach 1:
The patent changes the laser pulse width parameter from conventional values (nanoseconds or longer) to ultra-short pulse width (100 ps to 10^-6 ps). This parameter change enables the laser to cut the insulating layer without significant heat transfer, preventing melting and re-fusion while maintaining high manufacturing efficiency.
Solution Approach 2:
The patent employs periodic pulsed laser action instead of continuous laser irradiation. The ultra-short pulses deliver energy in discrete bursts, allowing the material to cool between pulses and preventing cumulative heat buildup that would cause melting and deformation of the insulating layer.
2Productivity
If the laser cutting speed is increased to improve productivity, then the manufacturing efficiency is improved, but the insulating layer lifting and current collector exposure occur
Solution Approach 1:
The patent changes the laser pulse width to ultra-short durations (100 ps to 10^-6 ps), which enables high cutting speeds without insulating layer lifting. The ultra-short pulse duration confines heat to the immediate cut zone, preventing thermal diffusion that would cause the insulating layer to lift or curl during high-speed cutting.
3Ease of manufacture
If conventional laser cutting is used, then the manufacturing process is simple, but debris is generated and the electrode tab profile is poor
Solution Approach 1:
The patent modifies the laser pulse width parameter to ultra-short durations, which changes the cutting mechanism from thermal melting to cold ablation. This parameter change eliminates debris generation and produces clean, precise cuts while maintaining process simplicity, as the same laser equipment is used with adjusted parameters.
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 approach significantly enhances the manufacturing efficiency and quality of the electrodes by preventing re-fusion, debris, and exposure of the current collector, thereby improving the stability and reliability of the battery.
Implementation Method 1
notching is performed using a laser having a pulse width of 100 ps to 10^-6 ps
Implementation Method 2
minimizes the melting of the insulating layer during cutting
Data Source
AI summary
A method for manufacturing an electrode for a secondary battery comprises the steps of (a) preparing an electrode sheet comprising a current collector partitioned into a coating portion and a non-coating portion and having an insulating layer laminated on the non-coating portion; and (b) forming an electrode tab by notching the non-coating portion on which the insulating layer is laminated. The notching is performed using a laser having a pulse width of 100 ps to 10−6 ps. An electrode for a secondary battery and an electrode manufacturing system used in the method described above is also provided.