Laser Beam Filtering Pattern for Parallel Supercapacitor Cutting
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Solution Overview
Problem
Current laser manufacturing processes are inefficient for producing high-precision supercapacitors with thin fringes due to limitations in cutting speed and depth, requiring extensive time and being impractical for mass production, especially when dealing with materials like graphene that demand precise and delicate cutting techniques.
Innovation Solution
A filtering device composed of multiple filtering patterns that split a single laser beam into numerous collimated child beams, allowing for simultaneous cutting across different areas of a part with improved accuracy and speed, reducing manufacturing time significantly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a narrow laser beam of limited power is used to cut thin fringes, then cutting precision is improved, but cutting speed and depth are reduced
Solution Approach 1:
The invention segments a single laser beam into multiple parallel child beams using a filtering device with a patterned sealant layer. This allows simultaneous cutting of multiple fringes across the graphene slab, dramatically increasing productivity while each individual child beam maintains the narrow width and limited power necessary for precise, damage-free cutting of thin fringes.
Solution Approach 2:
The invention transitions from one-dimensional sequential cutting (single beam moving along a path) to two-dimensional parallel cutting (multiple beams operating simultaneously across different spatial locations). The filtering device creates an array of child beams that can cut multiple fringes at once, adding a spatial dimension to the cutting process that resolves the speed-precision contradiction.
2Productivity
If laser power per unit area is increased to improve cutting speed, then productivity is improved, but the risk of damaging the delicate structure increases
Solution Approach 1:
By segmenting the laser beam into multiple child beams, the total laser power is distributed across many individual beams rather than concentrated in one. Each child beam delivers limited power per unit area, preventing thermal damage to the delicate graphene fringes, while the collective action of all child beams achieves high cutting speed and productivity.
3Productivity
If multiple laser beams are used to increase cutting speed, then productivity is improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The filtering device acts as an intermediary that automatically generates and positions multiple child beams in precise parallel relationships. The patterned sealant layer with gaps defines the exact positions and orientations of all child beams, eliminating the need for manual alignment of multiple independent laser sources. This intermediary structure ensures consistent alignment precision while enabling high productivity through parallel processing.
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 proposed solution enables rapid and precise manufacturing of supercapacitors, reducing production time by several thousand times compared to existing methods, making high-energy density supercapacitors more economically viable for mass production.
Implementation Method 1
the sealant layer is designed to absorb the laser beam; wherein the pattern in the sealant layer is formed by a plurality of gaps, the gaps designed to allow the laser beam to pass through
Implementation Method 2
the gaps designed to allow the laser beam to pass through the sealant layer and produce cuts on a substrate
Data Source
AI summary
A method and apparatus comprising a manufacturing process, equipment and a product. The manufacturing process and equipment configured to produce very high precision parts using a laser beam. Embodiments of the manufacturing process and equipment provide an improved method for the production of supercapacitors with critical dimensions on the order of one to fifty microns that can store electricity at very high energy densities using a modified laser beam. Using the manufacturing process and equipment, the proposed improvements allow the production of key parts thousands of times faster than what can be achieved using the usual process, resulting in a manufacturing time suitable for mass production.