Energy Storage Stack Laser Grooving for Folding and QC
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Solution Overview
Problem
The existing methods for forming and processing stacks for energy storage devices, such as solid-state thin film cells, are inefficient, making commercialization difficult due to complexities in forming electrical connections and ensuring quality control.
Innovation Solution
A method involving laser ablation to create grooves and registration features in the stack, allowing for efficient folding and quality control indication, potentially reducing the need for separate processing steps and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to form electrical connections and ensure quality control, then reliability is maintained, but productivity is reduced due to complex processing steps
Solution Approach 1:
The patent combines multiple processing functions into a single laser system that can perform both groove formation for electrical connections and registration feature creation for quality control. This merging of functions eliminates the need for separate processing steps, directly improving productivity while maintaining reliability through integrated processing.
Solution Approach 2:
The laser system is designed with multi-functionality to perform diverse tasks including forming grooves through electrode and electrolyte layers, creating registration features for fold points, and providing quality control indicators. This universal tool replaces multiple specialized devices, reducing processing complexity and enhancing production efficiency.
2Loss of time
If multiple separate processing steps are used for groove formation and registration features, then manufacturing precision is maintained, but loss of time increases
Solution Approach 1:
The laser system performs preliminary actions by forming both the grooves for electrical connections and the registration features for quality control in a single integrated process. This preliminary combined action eliminates subsequent separate processing steps, significantly reducing processing time while maintaining manufacturing precision through consistent laser-based fabrication.
Solution Approach 2:
Multiple feature formation operations are merged into a single laser processing pass. The system simultaneously or sequentially forms grooves through the electrode and electrolyte layers and creates registration features, eliminating the time loss associated with multiple separate processing steps while preserving manufacturing precision.
3Ease of manufacture
If a common laser source is used for groove formation and registration features, then cost is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The laser system employs dynamic control to differentiate between groove formation and registration feature creation. By dynamically adjusting laser parameters such as power, pulse duration, and scanning speed, the single laser source can precisely create different feature types with distinct characteristics, maintaining manufacturing precision while achieving cost-effectiveness through equipment consolidation.
Solution Approach 2:
The patent utilizes parameter changes in the laser operation to achieve different feature formations from a common laser source. By modifying laser parameters (power level, pulse frequency, beam focus, scanning speed), the system can create grooves of specific depths and registration features with distinct characteristics, ensuring manufacturing precision is maintained despite using a single laser source for multiple functions.
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 reliable and efficient production of energy storage devices by simplifying the folding process and reducing quality control procedures, while using a common laser source for cost-effectiveness.
Implementation Method 1
laser ablating the stack to form a plurality of first grooves in the stack
Implementation Method 2
laser ablating the stack to form the at least one registration feature
Data Source
AI summary
A method comprises obtaining a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method comprises laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves being through the first electrode layer and the electrolyte layer. The method comprises forming, in or on the stack, at least one registration feature, different from each of the plurality of first grooves. An apparatus and a stack for an energy storage device is also disclosed.