Laser Ablation for Battery Laminate Production
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Solution Overview
Problem
Conventional methods for producing all-solid battery laminates face challenges in reducing the number of production processes, preventing short-circuiting, and enhancing energy density, as they often result in errors due to multiple processing steps and difficulty in maintaining the integrity of thin solid electrolyte layers.
Innovation Solution
A method involving laser irradiation from the side of the first active material layer, where the solid electrolyte layer has a reflectance of 80% or more, allowing for the removal of part of the active material layer while preserving the solid electrolyte layer, thereby reducing the number of processes and preventing short-circuiting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production methods (wet-on-dry, wet-on-wet, or lamination pressing) are used to produce battery laminates, then the basic structure can be formed, but the number of production processes is large and manufacturing complexity increases
Solution Approach 1:
The patent combines multiple production steps into a single laser irradiation process. By irradiating the laminate with laser from the active material layer side, the method simultaneously achieves removal of excess active material and protection of the solid electrolyte layer, eliminating the need for separate cutting, pressing, and protection steps required by conventional methods.
Solution Approach 2:
The patent replaces mechanical cutting and pressing operations with laser irradiation. Instead of using mechanical tools to cut and shape the laminate layers, the invention uses laser energy to selectively remove material and achieve the desired geometry, reducing mechanical complexity and process steps.
2Reliability
If multiple processing steps are used to prevent short-circuiting, then short-circuit risks can be reduced, but the number of processes increases and productivity decreases
Solution Approach 1:
The patent extracts and removes excess active material layers that could cause short-circuits through laser ablation. By selectively removing material only where needed, the method prevents short-circuiting between electrodes while maintaining the integrity of the solid electrolyte layer, achieving reliability improvement without adding process steps.
Solution Approach 2:
The solid electrolyte layer acts as an intermediary that protects against short-circuiting. The laser irradiation method exploits the high reflectance of the solid electrolyte layer to prevent laser damage while allowing selective removal of active material, using the electrolyte layer itself as a protective mediator during the process.
3Quantity of substance
If the solid electrolyte layer is made thin to enhance energy density, then energy density improves, but the layer becomes vulnerable to breakage and manufacturing precision becomes difficult to maintain
Solution Approach 1:
The patent changes the laser irradiation parameters (wavelength, power, pulse duration) to match the optical properties of the solid electrolyte layer. By selecting a wavelength where the solid electrolyte has high reflectance, the method enables precise processing of thin layers without causing thermal damage or breakage, maintaining manufacturing precision while achieving high energy density.
Solution Approach 2:
The patent uses pulsed laser irradiation instead of continuous irradiation. The periodic pulse action allows heat to dissipate between pulses, preventing thermal accumulation that could damage thin solid electrolyte layers, thereby maintaining structural integrity during processing of thin, high-density configurations.
4Productivity
If laser irradiation is applied to remove active material layer, then the number of processes is reduced and productivity improves, but there is a risk of damaging the solid electrolyte layer
Solution Approach 1:
The solid electrolyte layer's high reflectance property serves as a natural protective intermediary. The laser wavelength is selected such that the solid electrolyte reflects most of the incident energy, preventing direct heating and damage. This allows the laser to safely remove active material adjacent to the electrolyte without compromising the electrolyte layer.
Solution Approach 2:
The laser irradiation is applied with localized precision, targeting only the excess active material regions while avoiding the solid electrolyte layer. The method exploits the spatial difference in optical absorption properties between the active material and solid electrolyte, applying energy locally where removal is needed while leaving the electrolyte untouched.
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
This approach enables the production of laminates with enhanced energy density and reduced short-circuiting risks by accurately removing part of the active material layer without damaging the solid electrolyte layer, allowing for a more efficient and precise battery construction.
Implementation Method 1
the reflectance of the laser by the solid electrolyte layer is 80% or more
Implementation Method 2
irradiating a laser to the laminate from a side of the laminate faced by the first active material layer to remove a part of the first active material layer
Data Source
AI summary
A method for producing a laminate for a battery in which a first active material layer and a solid electrolyte layer are stacked, includes irradiating the laminate with a laser from a side of the laminate faced by the first active material layer to remove a part of the first active material layer. The reflectance of the laser by the solid electrolyte layer is 80% or more.