Battery Separator Laser Cutting Under Applied Tension

Solution Overview

Problem

Increasing the scanning speed of laser beams to shorten the cutting time of a separator continuous body results in decreased energy density, making the cutting difficult, and relying on higher laser output intensity increases costs and risks thermal denaturation.

Innovation Solution

A separator cutting device that applies tension to the continuous body using a tension applying mechanism, combined with a laser irradiation unit to divide the body into individual separators, allowing for higher scanning speeds without increasing laser output intensity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the scanning speed of laser beams is increased to shorten cutting time, then productivity is improved, but energy density decreases making cutting difficult

Engineering Contradiction:

Improvecutting speedVSAvoidenergy density

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent introduces tension as an intermediary force that assists the laser beam in the cutting process. By applying tension to the separator continuous body in the conveyance direction, the mechanical stress concentrates at the laser irradiation point, enabling the laser to cut more effectively at higher scanning speeds without requiring increased energy density.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the output intensity of laser beams is increased to maintain cutting effectiveness at high speed, then cutting capability is improved, but equipment cost increases

Engineering Contradiction:

Improvecutting speedVSAvoidlaser equipment cost

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent changes the physical state and stress conditions of the separator continuous body by applying tension during the cutting process. This parameter change allows the use of lower laser output intensity while maintaining effective cutting at high scanning speeds, thereby reducing equipment cost requirements.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the output intensity of laser beams is increased to maintain cutting effectiveness, then cutting capability is improved, but thermal denaturation risk increases

Engineering Contradiction:

Improvecutting speedVSAvoidthermal denaturation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces tension as an intermediary force that assists the laser beam in the cutting process. By applying tension to the separator continuous body in the conveyance direction, the mechanical stress concentrates at the laser irradiation point, enabling the laser to cut more effectively at higher scanning speeds without requiring increased energy density.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical state and stress conditions of the separator continuous body by applying tension during the cutting process. This parameter change allows the use of lower laser output intensity while maintaining effective cutting at high scanning speeds, thereby reducing equipment cost requirements.

Inventive Principle:

Principle #35Parameter changes

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

Reduces cutting time and improves production lead time and throughput while maintaining cost-effectiveness by using tension to facilitate cutting with lower energy density, preventing thermal denaturation of the separators.

Implementation Method 1

a tension applying mechanism that applies tension to at least a portion of the continuous body in a conveyance direction of the continuous body

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

a laser irradiation unit that irradiates the portion of the continuous body onto which the tension has been applied by the tension applying mechanism with a laser beam so as to divide the continuous body into a plurality of separators

Methodology Applied

Scientific EffectLaser beam irradiation: Laser

Data Source

PatentUS12592452B2Separator cutting device and separator cutting method

Publication Date: 2026.03.31 PANASONIC HOLDINGS CORP

AI summary

A separator cutting device includes: a conveyance unit for conveying a continuous body of separators for batteries; a tension applying mechanism for applying tension to at least a portion of the continuous body in the conveyance direction of the continuous body; and a laser irradiation unit for irradiating the portion of the continuous body onto which the tension has been applied by the tension applying mechanism with a laser beam so as to divide the continuous body into a plurality of separators.