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

VSEngineering 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

Engineering Contradiction:
Improvecutting speedVSAvoidlaser beam transmittance
Core Design Contradiction:
ProductivityVSLoss of energy

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.

Inventive Principle:
Principle #10Preliminary action

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.

Inventive Principle:
Principle #35Parameter changes

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

Engineering Contradiction:
Improvecut surface qualityVSAvoidcutting time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

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.

Inventive Principle:
Principle #10Preliminary action

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.

Inventive Principle:
Principle #19Periodic action

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

Methodology Applied
Scientific EffectThermal heating: Heating

Implementation Method 2

cutting a strip-shaped separator layer-coated electrode by irradiation of a laser beam

Methodology Applied
Scientific EffectLaser heating: Laser

Data Source

PatentUS11673209B2Manufacturing method for an electrode with a separator layer and manufacturing apparatus for an electrode with a separator layer
Publication Date: 2023.06.13 TOYOTA JIDOSHA KK
  • US11673209B2 patent drawing
  • US11673209B2 patent drawing
  • US11673209B2 patent drawing

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.