Multi-Beam Laser Cutting of Metal Foil for Clean Battery Electrode Edges
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Solution Overview
Problem
Laser cutting of metal foils often results in uneven edges and lumps due to local melting, making it difficult to achieve high-quality cuts, especially when applied to battery electrodes where higher precision is required.
Innovation Solution
A laser cutting method and apparatus that uses a plurality of laser beams arranged to form spot groups separated in the scanning direction on the metal foil's surface, with a diffractive optical element to control the beam arrangement and power distribution, allowing for controlled energy delivery and reduced thermal effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single laser beam is used for cutting metal foil, then the cutting process is simple, but uneven edges and lumps occur due to local melting
Solution Approach 1:
The single laser beam is divided into multiple beams (e.g., 3-7 beams) that are arranged in a specific pattern. Each beam acts as an independent cutting element, and their combined effect provides more uniform energy distribution across the cut line, preventing localized overheating and lump formation while maintaining clean edges.
Solution Approach 2:
Multiple laser beams are merged into a single cutting operation, with all beams working simultaneously on the metal foil. The beams are coordinated to scan together along the cut path, providing distributed thermal energy that melts the material uniformly without creating the uneven edges associated with single-beam cutting.
2Productivity
If higher laser power is used to cut through metal foil efficiently, then cutting speed increases, but thermal damage and lump formation worsen
Solution Approach 1:
The total laser power required for efficient cutting is segmented across multiple beams. Each beam operates at a lower power level than a single high-power beam would require, but the cumulative power of all beams maintains high cutting speed. This distribution prevents any single location from receiving excessive thermal energy that would cause lumps or damage.
Solution Approach 2:
The multiple beams are arranged to provide non-uniform power distribution tailored to the specific cutting requirements. By adjusting the individual beam powers and their spatial arrangement, the system delivers optimal energy density at the cut front while preventing excessive heat accumulation that leads to thermal damage and lump formation.
3Manufacturing precision
If multiple laser beams are used to improve edge quality, then edge uniformity improves, but device complexity increases
Solution Approach 1:
A diffractive optical element (DOE) is introduced as an intermediary component that takes a single input laser beam and transforms it into multiple output beams with controlled spatial distribution and power ratios. This DOE-based approach is more compact and easier to align than traditional multi-beam systems using separate optical paths, reducing overall system complexity while achieving superior edge uniformity.
Solution Approach 2:
The diffractive optical element serves multiple functions simultaneously: it divides the single beam into multiple beams, controls the spatial arrangement of the beams, and adjusts the power distribution among the beams. This multi-functionality eliminates the need for separate optical components for each function, simplifying the overall system design and reducing complexity.
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 formation of high-quality edges by minimizing thermal damage and maintaining the integrity of active material layers on battery electrodes, reducing unevenness and lump formation while efficiently cutting through both covered and exposed portions of the metal foil.
Implementation Method 1
a diffractive optical element to control the beam arrangement and power distribution
Implementation Method 2
irradiating the front surface with laser light, wherein the laser light includes a plurality of beams
Implementation Method 3
melting the portion with energy of the laser light
Data Source
AI summary
A laser cutting method includes: performing laser cutting on a metal foil by scanning, on a front surface of the metal foil with respect to the front surface, the front surface while irradiating the front surface with laser light. The laser light includes a plurality of beams, and the plurality of beams are arranged to form a spot group including a plurality of spots separated in a relative scanning direction on the front surface.