Laser Cutting Secondary Battery Electrode Plates
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Solution Overview
Problem
The existing methods for manufacturing secondary batteries face challenges in achieving high-quality cut surfaces of electrode plates due to contamination from active materials and the occurrence of electrical shorts caused by burrs, which deteriorate the battery's reliability and performance.
Innovation Solution
A method involving the formation of an active material layer on collector plates, followed by selective removal of the layer using a laser beam to prevent contamination, and subsequent cutting of the plates with a laser to create a bead part that prevents electrical shorts, thereby enhancing the cut surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mold is used to cut the electrode plate, then the electrode plate can be cut to the required size, but the cutting quality deteriorates due to burr formation and active material scattering
Solution Approach 1:
The patent removes the active material layer from the cutting area before performing the cut. This extraction of the harmful substance (active material) from the cutting zone prevents it from scattering during the cutting process, thereby eliminating contamination and improving cut surface quality.
Solution Approach 2:
The patent performs preliminary removal of the active material layer before the cutting operation. By preparing the electrode plate in advance by removing the active material from the cutting area, the subsequent cutting process occurs without the presence of scatterable active material, preventing contamination and burr formation.
2Productivity
If a mold is used for repeated cutting operations, then production can continue, but the cutting blade becomes blunt and cutting quality deteriorates
Solution Approach 1:
The patent replaces the mechanical cutting system (mold with physical blade) with a laser-based cutting system. The laser beam cuts the electrode plate without physical contact, eliminating blade dulling and wear. This substitution maintains consistent cutting quality over extended production periods while preserving productivity.
3Reliability
If the active material layer is left on the electrode plate during cutting, then the battery capacity is maintained, but contamination occurs due to active material scattering
Solution Approach 1:
The patent selectively removes the active material layer only from the cutting area while preserving it in the active areas. This targeted extraction eliminates the source of contamination during cutting while maintaining the battery's functional capacity in the remaining active material regions.
Solution Approach 2:
The patent applies different treatments to different regions of the electrode plate. The cutting area has the active material layer removed to prevent contamination, while the active areas retain the full active material layer to maintain battery capacity. This local differentiation resolves the contradiction between reliability and contamination prevention.
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 improves the quality of the cut surface by preventing contamination and electrical shorts, leading to a more reliable and efficient secondary battery manufacturing process.
Implementation Method 1
an active material layer removing step of removing a part of the active material layer by irradiating a laser beam to the both surfaces of the collector plate
Implementation Method 2
a cutting step of cutting the collector plate by irradiating a laser beam onto the collector plate from which the active material layer has been removed
Implementation Method 3
A bead part having a circular or oval cross-section may be formed on a cut surface of the current collector plate by fusing the current collector plate by the laser beam irradiated in the cutting step and cooling
Data Source
AI summary
The present invention relates to a method for manufacturing a secondary battery and a secondary battery using the same, which can improve the quality of a cut surface of an electrode plate and improve the reliability of the secondary battery. For example, disclosed is a method for manufacturing a secondary battery, the method comprising: an active material layer forming step of forming an active material layer by coating an active material on both surfaces of a collector plate; an active material layer removing step of removing a part of the active material layer by irradiating a laser beam to the both surfaces of the collector plate; and a cutting step of cutting the collector plate by irradiating a laser beam onto the collector plate from which the active material layer has been removed in the active material layer removing step.