Laser Cathode Cutting Device for Continuous Lithium Battery Production
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Solution Overview
Problem
The existing mold cutter-based method for manufacturing cathode sheets is inefficient, requiring frequent line stoppages, high production costs, and limited flexibility in producing cathodes of various shapes and sizes due to the need for multiple mold cutters, which increases production time and decreases yield.
Innovation Solution
A laser-based cathode cutting device that uses a laser oscillator emitting a focused beam with a focal spot size of 10 μm to 50 μm and energy density of at least 25 J/cm², allowing for continuous cutting of cathode sheets without stopping the production line, and includes a focusing lens, un-winder, winder, sheet guide, and adjustable optical components to maintain precise cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold cutter is used to cut the cathode sheet, then cutting quality is high, but production time increases and yield decreases due to frequent line stoppages for mold replacement
Solution Approach 1:
The patent replaces the mechanical mold cutter system with a laser-based cutting system. The laser oscillator generates a laser beam that is focused by a lens to cut the cathode sheet, eliminating the need for physical contact between the cutter and the material. This substitution allows for continuous cutting without line stoppages while maintaining cutting quality through precise laser focus control with a focal spot size of 10-50 μm and energy density of at least 25 J/cm².
Solution Approach 2:
The laser cutting system provides universal functionality by being able to cut cathode sheets of various shapes and sizes using a single device. By adjusting the laser beam path and focusing parameters, the system can accommodate different cutting patterns without requiring multiple specialized mold cutters, thus eliminating the need for frequent mold replacements and line stoppages.
2Adaptability or versatility
If multiple mold cutters are provided for various shapes and sizes, then cutting versatility is improved, but production cost increases and operation rate decreases
Solution Approach 1:
The laser cutting system serves as a universal cutting device that can handle various cathode sheet shapes and sizes with a single setup. The system uses a computer-controlled laser beam path that can be programmed to follow different cutting patterns, replacing the need for multiple physical mold cutters. This eliminates line stoppages for mold replacement and maintains high operation rates while providing cutting versatility.
Solution Approach 2:
The laser cutting system employs dynamic control of the laser beam path and focusing position to adapt to different cutting requirements. The beam can be dynamically redirected and refocused during operation to accommodate various shapes and sizes, providing versatility without requiring physical replacement of cutting tools, thus maintaining continuous production flow.
3Manufacturing precision
If a mold cutter is used, then cutting precision is maintained, but manufacturing cost increases due to expensive mold cutters
Solution Approach 1:
The patent replaces expensive mechanical mold cutters with a laser-based system. The laser oscillator and focusing lens assembly is significantly less expensive than precision-machined mold cutters while delivering comparable or superior cutting precision. The laser system achieves precise cutting through controlled focal spot size (10-50 μm) and energy density (at least 25 J/cm²) without requiring costly physical tooling.
Solution Approach 2:
The laser cutting system uses a consumable approach where the laser beam itself is the cutting tool, eliminating the need for durable, expensive mold cutters. The laser system has no physical contact with the material, so there is no wear on cutting edges, and the system can be reprogrammed for different cuts without replacing physical tools, reducing overall manufacturing costs while maintaining precision.
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 laser-based system enables high-yield, continuous production of cathodes with various shapes, reducing production costs and maintaining cutting quality by optimizing focal spot size and energy density, thus enhancing operational efficiency and flexibility.
Implementation Method 1
a laser oscillator emitting a laser beam; and a focusing lens focusing the laser beam emitted from the laser oscillator and radiating a focused laser beam to a cathode sheet to cut the cathode sheet
Implementation Method 2
a focusing lens focusing the laser beam emitted from the laser oscillator and radiating a focused laser beam to a cathode sheet to cut the cathode sheet, wherein the a size of a focal spot of the laser beam radiated to a surface of the cathode sheet is about 10 μm to about 50 μm, and energy density of the focal spot is equal to or higher than about 25 J/cm2
Data Source
AI summary
The present invention relates to a lithium secondary battery, and more specifically to a lithium secondary battery having a multi-directional lead-tab structure. The lithium secondary battery of the present invention includes: an electrode assembly which is formed by alternately laminating an electrode plate having a current collector, an active material, and a tab, and an isolation layer; a lead which is electrically connected to the tab; and a battery case, wherein the lead is divided into an anode lead and a cathode lead, and at least two or more anode leads and cathode leads are provided. The battery of the present invention uses the same lead-tab size as the prior art and is suitable for use with high current.