Multi-Wavelength Laser Beam Combining for Stacked Material Processing
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Solution Overview
Problem
Conventional laser notching devices for secondary battery electrodes are inefficient due to inadequate consideration of laser beam paths, leading to decreased efficiency and increased costs from frequent machine breakdowns, and struggle to simultaneously cut both the electrode film and active layer using single-wavelength lasers, complicating the processing apparatus and increasing manufacturing costs.
Innovation Solution
A processing apparatus using multiple lasers with beam modifiers and combiners that adjust irradiation conditions in real time, combining laser beams of different wavelengths to enhance absorption and reduce reflectance, allowing simultaneous processing of surfaces and interiors with improved precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams with different wavelengths are used to process different layers simultaneously, then processing speed and efficiency are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple laser beams with different wavelengths into a single processing path using beam combining technology. This allows simultaneous processing of different layers (electrode film and active material) with appropriately selected wavelengths, achieving high-speed processing while consolidating multiple laser sources into one integrated system rather than requiring separate processing stations.
Solution Approach 2:
The processing apparatus is designed with multi-functionality to handle different material layers using different laser wavelengths. The system can selectively process the electrode film with one wavelength and the active material with another wavelength, making a single apparatus capable of performing multiple processing functions that would otherwise require separate devices.
2Productivity
If laser beam path is not optimized, then device complexity is reduced, but productivity decreases due to frequent breakdowns and inefficient work arrangement
Solution Approach 1:
The patent implements preliminary optimization of the laser beam path and work arrangement before actual processing begins. The system pre-configures the beam trajectories, focuses, and timing sequences to ensure efficient processing from the start, preventing breakdowns and maximizing laser efficiency without requiring complex real-time adjustments during operation.
3Manufacturing precision
If single-wavelength laser is used, then device complexity is reduced, but manufacturing precision decreases because both electrode film and active layer cannot be cut simultaneously
Solution Approach 1:
The patent applies local quality by selecting specific laser wavelengths that are optimally absorbed by particular materials. The electrode film is processed with a wavelength suited to its material properties, while the active material layer is processed with a different wavelength that maximizes absorption and cutting precision for that specific material, thereby achieving high manufacturing precision for each layer.
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 efficient processing of stacked layers with different materials by optimizing laser beam absorption, improving processing speed and precision, and reducing manufacturing costs by allowing simultaneous cutting, welding, and patterning of electrode films and other materials.
Implementation Method 1
a plurality of laser generators for generating a plurality of laser beams; beam modifiers for maintaining or modifying a shape of each laser beam in real time
Implementation Method 2
irradiating laser beams having different wavelengths to the object to be processed... to lower a reflectance of the laser beams and increase an absorption rate of the laser beams
Implementation Method 3
beam modifiers for maintaining or modifying a shape of each laser beam in real time... to combine the laser beams having a wavelength absorbed on the surface of the object to be processed and the laser beams having different wavelengths absorbed inside the object to be processed to have different diameters
Data Source
AI summary
A processing apparatus using a plurality of lasers includes a plurality of laser generators that generate multiple laser beams, a plurality of beam modifiers that maintain a shape of each laser beam or modify the shape in real time, beam combiners that combine multiple laser beams modified by the plurality of beam modifiers, and a control unit that changes an irradiation condition of each laser beam based on a processing condition of an object to be processed to control driving of each laser generator and the beam modifier in real time, thereby irradiating laser beams having different wavelengths to a single object to be processed or an object to be processed in which the same or different materials are stacked to process the single object to be processed or the object to be processed.