Preheating Separator Layer for Laser Cutting Efficiency
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Solution Overview
Problem
The existing laser cutting technique for electrodes with a separator layer coated with thermoplastic resin particles, such as polyethylene, is inefficient due to low transmittance of the laser beam, leading to slow cutting processes.
Innovation Solution
A method and apparatus that preheat the separator layer before cutting, enhancing the transmittance of the laser beam through the thermoplastic resin particles, allowing for quicker cutting by increasing the energy quantity that reaches the electrode mixture layer and current collecting member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is irradiated to cut a separator layer-coated electrode, then the electrode can be cut, but the cutting speed is slow due to low laser beam transmittance through the thermoplastic resin particles
Solution Approach 1:
The patent applies preliminary action by preheating the separator layer before laser cutting. The preheating unit heats the thermoplastic resin particles in the separator layer to a temperature where they become more transparent to the laser beam (typically above the glass transition temperature), thereby improving laser beam transmittance and enabling faster cutting speeds. This preliminary thermal treatment resolves the contradiction by preparing the material in advance to reduce energy loss during the subsequent cutting process.
Solution Approach 2:
The patent employs parameter changes by altering the temperature of the thermoplastic resin particles in the separator layer. By changing the temperature parameter from ambient to elevated (above glass transition temperature), the optical properties of the resin change, increasing laser beam transmittance. This parameter change directly addresses the energy loss issue and enables higher productivity in the cutting process.
2Manufacturing precision
If the laser beam irradiation time is increased to improve cutting quality, then the cut surface quality improves, but the cutting time increases significantly
Solution Approach 1:
The preheating of the separator layer before cutting serves as a preliminary action that prepares the material for efficient laser cutting. By preheating the thermoplastic resin particles, the material becomes more receptive to laser energy, allowing for faster cutting speeds while maintaining acceptable cut surface quality. This eliminates the need for prolonged irradiation times and resolves the time-quality trade-off.
Solution Approach 2:
The patent implements periodic action through the two-stage process: first preheating the separator layer, then performing the actual laser cutting. This periodic application of thermal energy in distinct phases (preheating phase followed by cutting phase) allows the material to be optimally prepared before the cutting action, achieving both good cut quality and reduced total processing time.
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 preheating process significantly reduces the time required for cutting the separator layer-coated electrodes, minimizing the melt width of the separator layer and preventing internal short circuits in batteries, thus improving the efficiency and accuracy of the cutting process.
Implementation Method 1
preheating the separator layer before cutting, enhancing the transmittance of the laser beam through the thermoplastic resin particles
Implementation Method 2
cutting a strip-shaped separator layer-coated electrode by irradiation of a laser beam
Data Source
AI summary
A manufacturing method and a manufacturing apparatus for a separator layer-coated electrode are provided capable of shortening the time required to cut out a separator layer-coated electrode with a laser beam. In a cutting process, a laser beam is irradiated to a laser irradiation target portion of a strip-shaped separator layer-coated electrode from a front-side separator layer side to cut a strip-shaped separator layer-coated electrode. Prior to the cutting process, a preheating process is conducted to preheat the front-side separator layer in the laser irradiation target portion.


