High Speed, Automated Lithium Ion Laser Electrode Cutter

Manufacturing technologies for Li-ion batteries have not kept pace with the rapid innovation of high energy Li-ion chemistries, inhibiting battery performance and compromising safety. Recent studies have shown that one of the major reasons for Li-ion battery failure (self-discharge, catastrophic failure etc.) can be attributed to manufacturing defects caused by mechanical (metal) die cutters, which leave metal shards between the electrodes and separators. In addition, uneven, low tolerance edges, burrs, debris and low reliability lead to cell failure and less than optimal performance. Finally, dies represent life-time buy systems, leading to inflexible manufacturing and serious impediments to agile design modifications. To address this need, ADA Technologies, Inc., in partnership with Laser Marks Company, a laser systems integrator, proposes the design of a low-cost, automated, high-speed/high-throughput electrode pulsed laser cutter capable of producing high quality Li-ion electrodes in an additive manufacturing environment. Through the implementation of the latest in laser technology and scanning systems coupled with innovative design and automation, we envision the development of a low-cost, flexible, high quality laser cutter capable of eliminating sharp edges, burrs and debris to enable safe operation, minimizing the chances of cell failure and thermal runaway.