Roll-to-Roll Electrode Tab Notching With Meander Correction

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Solution Overview

Problem

Existing secondary battery electrode manufacturing processes are slow and inefficient, with issues such as meandering, physical interference, and poor quality control, leading to reduced productivity and reliability.

Innovation Solution

A roll-to-roll manufacturing method utilizing laser notching and meander correction, combined with ultrasonic cleaning and vision inspection, to form electrode tabs and improve the manufacturing process efficiency and quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional electrode manufacturing processes are used, then manufacturing simplicity is maintained, but production speed is slow and productivity is low

Engineering Contradiction:

Improveproduction speedVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical notching methods with laser scanning technology. The laser scanner performs notching processing without physical contact, eliminating mechanical interference and enabling high-speed processing. This substitution of mechanical systems with optical/thermal systems directly increases production speed while maintaining process capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameters by using laser energy instead of mechanical force. The laser parameters (power, scanning speed, focal position) are optimized to achieve clean notches at high speeds. This parameter change from mechanical to thermal/optical domain enables faster processing without the constraints of mechanical tool wear and physical interference.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If physical notching methods are used, then manufacturing simplicity is maintained, but physical interference occurs and processing accuracy deteriorates

Engineering Contradiction:

Improvenotching accuracyVSAvoidphysical interference

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates physical interference by replacing mechanical notching tools with a laser scanning system. The laser beam performs notching without physical contact with the electrode material, eliminating issues such as tool wear, mechanical stress, and physical interference that affect traditional methods. This results in higher manufacturing precision and cleaner processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If multiple separate processes are used for notching and molding, then process quality is maintained, but the number of processes increases and productivity decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidprocess integration

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent merges the notching process and molding process into a single integrated laser scanning operation. The laser scanner performs both functions simultaneously or in sequence without requiring separate processing steps, equipment, or setup changes. This consolidation reduces the total number of processes, eliminates transfer time between stations, and increases overall production efficiency while maintaining quality standards.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If high-speed laser processing is used, then productivity is improved, but processing precision may deteriorate due to speed

Engineering Contradiction:

Improveprocessing speedVSAvoidprocessing accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs dynamic control of the laser scanning system, where scanning speed, laser power, and focal position are adjusted in real-time based on the processing requirements. The system maintains optimal processing parameters throughout high-speed operation, ensuring consistent notch quality and precision even at increased speeds. This dynamic adaptation allows the system to achieve both high productivity and high precision simultaneously.

Inventive Principle:

Principle #15Dynamics

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 enables high-speed production of high-quality electrode materials by minimizing physical interference and ensuring accurate processing, thereby increasing productivity and reliability.

Implementation Method 1

notching the electrode material by at least one laser scanner positioned at one or both ends of a width direction of the electrode material

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

ultrasonic cleaning for applying ultrasonic waves to the electrode material

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS20250316677A1Roll-to-roll manufacturing method of electrodes for secondary batteries

Publication Date: 2025.10.09 SK ON CO LTD

AI summary

Proposed is a roll-to-roll manufacturing method of electrodes for secondary batteries including material supplying for supplying an electrode material from an unwinder, meander correcting for correcting meandering in a movement path of the electrode material, notching processing for forming an electrode tab shape by processing a tab fabrication area of the electrode material, cleaning the electrode material, vision inspection for determining whether the electrode material is of good quality, and electrode material winding for winding the electrode material with a rewinder.