CN116648324A - Method for scribing electrode structure groups in web material by laser - Google Patents

Abstract

A method of scoring groups of electrode structures in a web (104) is disclosed. The web (104) has a web longitudinal direction, a web transverse direction, an electrochemically active layer, and a conductive layer. The method includes laser machining the web (104) with a laser beam (302) at least in a cross-web direction to scribe members of the electrode structure groups in the web (104) without releasing the scribed members from the web (104), and forming alignment features in the web (104) that are adapted to locate each scribed member of the electrode structure groups in the web (104).

Description

Method for scribing electrode structure groups in web material by laser

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application number 63/081,686, filed on 9/22/2020, and U.S. provisional patent application number 63/080,345, filed on 18/9/2020. Reference is made to U.S. patent application Ser. No. 16/533,082 filed on 8/6/2019, U.S. patent application Ser. No. 16/763,078 filed on 11/5/2020, U.S. provisional patent application Ser. No. 62/586,737 filed on 11/15/2017, and U.S. provisional patent application Ser. No. 62/715,233 filed on 8/6/2018. The entire contents of each of these applications are incorporated herein by reference.

Technical Field

The field of the present disclosure relates generally to energy storage technology, such as battery technology. More specifically, the field of the disclosure relates to systems and methods for producing energy storage systems, such as electrodes for batteries (including lithium-based batteries).

Background

Lithium-based secondary batteries are ideal energy sources due to their relatively high energy density, power and shelf life. Examples of lithium secondary batteries include nonaqueous batteries, such as lithium ion and lithium polymer batteries.

Known energy storage devices such as batteries, fuel cells and electrochemical capacitors typically have a two-dimensional layered structure, such as a planar laminate structure or a spiral wound (i.e., jelly roll) laminate structure, wherein the surface area of each laminate is approximately equal to its geometric footprint (ignoring porosity and surface roughness).

Fig. 1 shows a cross-sectional view of a known layered secondary battery, generally designated 10. The battery 10 includes a positive current collector 15 in contact with a positive electrode 20. Negative electrode 25 is spaced apart from positive electrode 20 by separator 30. Negative electrode 25 is in contact with a negative electrode current collector 35. As shown in fig. 1, the battery 10 is formed in a laminate form. The stack is sometimes covered with another separator layer (not shown) over the negative current collector 35, and then the stack is rolled up and placed into a can (not shown) to assemble the cell 10. During charging, carrier ions (typically lithium) leave positive electrode 20 and pass through separator 30 into negative electrode 25. Depending on the anode material used, carrier ions either intercalate (e.g., are located in the matrix of anode 25 material without forming an alloy) or alloy with anode 25 material. During discharge, carrier ions leave anode 25 and pass through separator 30 back into cathode 20.

The three-dimensional secondary battery may provide higher capacity and life as compared to the layered secondary battery. However, the production of such three-dimensional secondary batteries presents manufacturing and cost challenges. The precision manufacturing techniques used so far can produce secondary batteries with improved cycle life, but at the cost of productivity and manufacturing costs. However, when the known manufacturing technology is accelerated, an increase in the number of defects, capacity loss, and a reduction in the life of the battery are caused.

In the rocking chair type battery cell, both the positive and negative electrodes of the secondary battery contain a material into and from which carrier ions (e.g., lithium) are intercalated. When the battery is discharged, carrier ions are extracted from the negative electrode and are embedded in the positive electrode. When the battery is charged, carrier ions are extracted from the positive electrode and are intercalated into the negative electrode.

Silicon is a promising candidate for replacing carbonaceous materials as anodes due to its high specific capacity. For example, by LiC ₆ The graphite anode formed may have a specific capacity of about 370 milliamperes per gram (mAh/g) and is composed of Li ₁₅ Si ₄ The crystalline silicon anode formed may have a specific capacity of about 3600mAh/g, approximately 10 times that of a graphite anode. However, the use of silicon anodes is limited because the volume of silicon varies greatly (e.g., 300%) when Li carrier ions are intercalated into the silicon anode. This increase in volume and the cracking and comminution associated with the charge and discharge cycles limit the use of silicon anodes in practice. In addition, the use of the silicon anode is limited due to a capacity loss during the initial formation of the secondary battery using the silicon anode, which is caused by the poor Initial Coulombic Efficiency (ICE) of the silicon anode.

Accordingly, it is desirable to improve the performance of secondary batteries using silicon-based anodes, and more particularly, to alleviate the problems of silicon anodes due to ICE differences.

Disclosure of Invention

In one embodiment, a method for scoring groups of electrode structures in a web is disclosed. The web has a web longitudinal direction, a web transverse direction, an electrochemically active layer, and a conductive layer. The method comprises the following steps: laser machining the web at least in a cross-web direction to scribe members of the electrode structure groups in the web without releasing the scribed members from the web; and forming in the web an alignment feature adapted to locate each scored member of the group of electrode structures in the web.

In another embodiment, another method for scoring groups of electrode structures in a web is disclosed. The web has a web longitudinal direction, a web transverse direction, an electrochemically active layer, and a conductive layer. The method includes feeding the web to a cutting station and cutting the web at the cutting station at least in a cross-web direction to scribe members of the electrode structure group in the web without releasing the scribed members from the web. The method further includes cutting an alignment feature in the web, the alignment feature adapted to locate each scored member of the group of electrode structures in the web.

In another embodiment, another method of scoring groups of electrode structures in a web is disclosed. The web has a web longitudinal direction, a web transverse direction, an electrochemically active layer, and a conductive layer. The method includes feeding the web to a laser cutting system, cutting registration features in the web using the laser cutting system, and establishing a position of the web using the at least one registration feature. The method further includes performing at least one of a cutting action and an ablation action on the web based on the established position.

In another embodiment, a web comprising an electrochemically active layer and a conductive layer is disclosed. The web has a scored group of electrode structures, each electrode structure of the scored group of electrode structures being spaced apart from an adjacent electrode structure by a web cross-cut in the web. The web also includes an alignment feature adapted to position each scored electrode structure of the group of electrode structures in the web.

In another embodiment, the web has scored groups of separator structures. Each separator in the scored group of separators is spaced apart from an adjacent separator by a cross-web cut in the web. The web also includes an alignment feature adapted to locate each scored separator of the group of separators in the web.

Drawings

Fig. 1 is a sectional view of a conventional layered battery.

Fig. 2 is a schematic diagram of one suitable embodiment of an electrode manufacturing system according to the present disclosure.

Fig. 3 is an enlarged schematic view of one suitable embodiment of a laser system according to the present disclosure.

Fig. 4 is an isometric view of one suitable embodiment of a cutting plenum according to the present disclosure.

Fig. 5 is a top view of an exemplary web of base material that is processed by the electrode manufacturing system of the present disclosure to form an electrode.

Fig. 6 is a top view of an exemplary web of base material with electrode patterns formed thereon.

Fig. 6A is a perspective view of a portion of a base material web as an exemplary negative electrode.

Fig. 6B is a perspective view of a portion of a base material web as an exemplary positive electrode.

Fig. 7 is an enlarged top view of a portion of a base material web on which an exemplary electrode pattern is formed.

Fig. 8 is an isometric view of a base material of an electrode material web that forms a containing electrode patterns after processing by the electrode manufacturing system of the present disclosure.

Fig. 8A is a top view of a portion of the electrode material web of fig. 8.

Fig. 9 is an isometric view of one suitable embodiment of a rewind roll of the electrode manufacturing system of the present disclosure.

Fig. 10 is a top view of one suitable embodiment of a brushing station of the present disclosure.

Fig. 11 is a side view of the exemplary brushing station of fig. 10.

Fig. 12 is an isometric view of one suitable embodiment of an inspection station according to the present disclosure.

Fig. 13 is a top view of a suction cup according to one suitable embodiment of the present disclosure.

Fig. 14 is a schematic view of a stacked arrangement according to the present disclosure.

Fig. 15 is a cross-sectional view of a multilayer electrode stack according to the present disclosure.

Fig. 16A is a side view of a multilayer electrode stack according to the present disclosure.

Fig. 16B is a partial top view of the multi-layer electrode stack of fig. 16A.

FIG. 16C is a partial top view of the multi-layer stack of FIG. 16A after the second perforation has been ruptured.

Fig. 17 is an isometric view of a stacked battery cell according to the present disclosure.

Fig. 18A and 18B are continuous isometric views of a stacked battery cell with a battery package disposed thereon.

Detailed Description

Definition of the definition

As used herein, "a," "an," and "the" (i.e., in the singular) refer to plural referents unless the context clearly dictates otherwise. For example, in one example, reference to "an electrode" includes a single electrode and a plurality of like electrodes.

As used herein, "about" and "approximately" refer to ± 10%, ±5% or ± 1% of the value. For example, in one example, about 250 μm will include 225 μm to 275 μm. As a further example, in one example, about 1000 μm will include 900 μm to 1,100 μm. Unless otherwise indicated, all numbers expressing quantities (e.g., measurement, etc.) and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations. Each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

As used herein in the context of a secondary battery, "anode" refers to the negative electrode in the secondary battery.

As used herein, "anode material" or "anode activity" refers to a material suitable for use as a negative electrode of a secondary battery.

As used herein, "capacity" or "C" refers to the amount of charge that a battery (or a battery sub-portion comprising one or more pairs of electrode structures and counter electrode structures forming a bilayer) can deliver at a predetermined voltage unless the context clearly indicates otherwise.

As used herein in the context of a secondary battery, "cathode" refers to the positive electrode in the secondary battery.

As used herein, "cathode material" or "cathode activity" refers to a material suitable for use as the positive electrode of a secondary battery.

As used herein in the context of the state of a secondary battery, the "state of charge" refers to a state in which the secondary battery is charged to at least 75% of its rated capacity, unless the context clearly indicates otherwise. For example, the battery may be charged to at least 80% of its rated capacity, at least 90% of its rated capacity, or even at least 95% of its rated capacity, such as 100% of its rated capacity.

As used herein, "composite" or "composite" refers to a material that comprises two or more constituent materials, unless the context clearly indicates otherwise.

"conversion chemical active material" or "conversion chemical material" refers to a material that undergoes chemical reactions during charge and discharge cycles of a secondary battery.

As used herein, a "counter electrode" may refer to a negative or positive electrode (anode or cathode) of a secondary battery that is opposite to the electrode, unless the context clearly indicates otherwise.

As used herein, a "counter electrode current collector" may refer to the negative or positive (anode or cathode) current collector of a secondary battery that is opposite to the electrode current connector/electrode current collector, unless the context clearly indicates otherwise.

"cycling" as used herein in the context of cycling a secondary battery between a charged state and a discharged state refers to charging and/or discharging the battery such that the battery moves in a cycle from a first state (i.e., a charged or discharged state) to a second state opposite the first state (i.e., a charged state if the first state is a discharged state; a discharged state if the first state is a charged state), and then moving the battery back to the first state to complete the cycle. For example, when in a charge cycle, a single cycle of the secondary battery between a charged state and a discharged state may include charging the battery from the discharged state to the charged state and then discharging to return to the discharged state, thereby completing the cycle. While in the discharge cycle, a single cycle may also include discharging the battery from a charged state to a discharged state and then charging to return to the charged state, thereby completing the cycle.

As used herein in connection with a negative electrode, the "discharge capacity" refers to the amount of carrier ions that can be extracted from the negative electrode and inserted into the positive electrode during a battery discharge operation between a predetermined set of cell end-of-charge voltage limits and end-of-discharge voltage limits, unless the context clearly indicates otherwise.

As used herein in the context of the state of a secondary battery, the "discharge state" refers to a state in which the secondary battery is discharged to less than 25% of its rated capacity, unless the context clearly indicates otherwise. For example, the battery may be discharged to less than 20% of its rated capacity, such as less than 10% of its rated capacity, or even less than 5% of its rated capacity, such as to 0% of its rated capacity.

As used herein, "electrochemically active material" refers to either an anode active material or a cathode active material.

As used herein, "electrode" may refer to the negative electrode or positive electrode of a secondary battery unless the context clearly indicates otherwise.

As used herein, "electrode current collector" may refer to either an anode (e.g., negative electrode) current collector or a cathode (e.g., positive electrode) current collector.

As used herein, "electrode material" may refer to either anode material or cathode material unless the context clearly indicates otherwise.

As used herein, "electrode structure" may refer to either an anode structure (e.g., a negative electrode structure) or a cathode structure (e.g., a positive electrode structure) suitable for use in a battery unless the context clearly indicates otherwise.

As used herein, "electrolyte" refers to a nonmetallic liquid, gel, or solid material in which the current is carried by the movement of ions suitable for use in a battery, unless the context clearly indicates otherwise.

As used herein, "longitudinal axis," "transverse axis," and "vertical axis" refer to axes that are perpendicular to each other (i.e., each axis is orthogonal to each other). For example, as used herein, "longitudinal axis," "transverse axis," and "vertical axis" are similar to a Cartesian coordinate system used to define three-dimensional aspects or orientations. Accordingly, the description herein of elements of the presently disclosed subject matter is not limited to one or more specific axes for describing three-dimensional orientations of the elements. In other words, these axes may be interchangeable when referring to the three-dimensional aspects of the presently disclosed subject matter.

As used herein, "microstructure" may refer to the structure of a surface of a material as revealed by an optical microscope at about 25 x magnification or more, unless the context clearly indicates otherwise.

As used herein, "microporous" may refer to a material containing pores having diameters less than about 2 nanometers, unless the context clearly indicates otherwise.

As used herein, "macroporous" may refer to a material containing pores having a diameter greater than about 50 nanometers, unless the context clearly indicates otherwise.

As used herein, "nanoscale" or "nanoscale" may refer to structures ranging in length from about 1 nanometer to about 100 nanometers.

As used herein, "polymer" may refer to a substance or material composed of repeating subunits of a macromolecule, unless the context clearly indicates otherwise.

Herein, "reversible coulombic capacity" in relation to an electrode (i.e., positive, negative, or auxiliary electrode) refers to the total electrode capacity of carrier ions available for reversible exchange with a counter electrode.

As used herein, "void fraction" or "porosity" or "void volume fraction" refers to a measure of void (i.e., empty) space in a material and is the fraction of void volume to the total volume of the material, which is in the range of 0 to 1, or expressed as a percentage of 0% to 100%.

By "weakened area" is meant a portion of the web that has undergone a processing operation such as scoring, cutting, perforating, etc., such that the local breaking strength of the weakened area is lower than the breaking strength of the non-weakened area.

Detailed Description

Embodiments of the present disclosure relate to an apparatus, system, and method for producing an electrode member of a battery (e.g., a three-dimensional secondary battery), which may increase a manufacturing speed of the electrode member while maintaining or increasing a battery capacity and a battery life, and reduce defects occurring during manufacturing.

An exemplary system for the production of an electrode member (including an electrode and a separator) of a battery will be described with reference to fig. 2. An electrode production (or manufacturing) system, generally designated 100, includes a plurality of discrete stations, systems, components or equipment whose function is to enable efficient production of precision electrodes for batteries. The production system 100 is first generally described with reference to fig. 2, and additional details of each component are subsequently further described after introducing a broader production system 100.

In the exemplary embodiment shown, production system 100 includes a base material unwind roll 102 for holding and unwinding a web of base material 104. The web of base material 104 may be a web of electrode material (i.e., anode material web 502 or cathode material web 504), a web of separator material, or the like, suitable for producing a material for a secondary battery electrode assembly. The web of base material 104 is a sheet material that has been wound into a roll form with a central through hole sized for placement on the base material unwind roll 102. In some embodiments, the web of base material 104 is a multi-layer material including, for example, an electrode current collector layer (i.e., anode current collector layer 506 or cathode current collector layer 510) and an electrochemically active material layer (i.e., anode active material layer 508 or cathode active material layer 512) on at least one major surface thereof, in other embodiments, the web of base material 104 may be a single layer (e.g., a separator material web). The base unwind roll 102 may be formed of a metal, metal alloy, composite, plastic, or any other material that allows the production system 100 to function as described herein. In one embodiment, the base material unwind roll 102 is made of stainless steel and has a diameter of 3 inches (76.2 millimeters).

As shown in the embodiment of fig. 2, the web of base material 104 passes through edge guides 106 to facilitate unwinding of the web of base material 104. In one embodiment, edge guide 106 uses a through-beam type optical sensor to determine the position of one edge of the web of base material 104 relative to a fixed reference point. Feedback is sent from the edge guides 106 to a "web turning" roller (typically the base material unwind roller 102) that will move in a direction perpendicular to the web longitudinal direction of the base material 104. In this embodiment, the web of base material 104 then passes around idler wheel 108a and into the docking station 110. Idler 108a (which may also be referred to as an idler roller) helps to maintain proper positioning and tension of the web of base material 104, as well as to change the direction of the web of base material 104. In the embodiment shown in fig. 2, the idler wheel 108a receives the web of base material 104 in a vertical direction and the web of base material is partially wound around the idler wheel 108a such that the web of base material 104 exits the idler wheel 108a in an output direction that is substantially 90 degrees from the input direction. However, it should be understood that the input and output directions may vary without departing from the scope of the present disclosure. In some embodiments, the production system 100 may use multiple idler wheels 108a-108x to change the direction of the web of base material 104 as it is conveyed through the production system 100 one or more times. Idler pulleys 108a-108x may be formed from metals, metal alloys, composites, plastics, rubber, or any other material that allows production system 100 to function as described herein. In one embodiment, the idlers 108a-108x are made of stainless steel and have dimensions of 1 inch (25.4 millimeters) diameter by 18 inches (457.2 millimeters) in length.

The splicing station 110 is configured to facilitate splicing (e.g., connecting) two separate webs together. In one suitable embodiment, when the first web of base material 104 is unwound such that the trailing edge (not shown) of the web of base material 104 stops within the splicing station 110, the leading edge (not shown) of the second web of base material 104 is unwound into the splicing station 110 such that the trailing edge of the first web of base material 104 and the leading edge of the second web of base material 104 are adjacent to each other. The user may then apply an adhesive, such as tape, to join the leading edge of the second web of base material 104 to the trailing edge of the first web of base material 104 to form a seam between the two webs and create a continuous web of base material 104. Such a process may be repeated for a number of webs of base material 104, as directed by the user. Thus, the splicing station 110 allows the possibility of splicing together multiple webs of base material to form one continuous web. It should be appreciated that in other embodiments, the user may splice webs of the same or different materials together if desired.

In one suitable embodiment, after leaving the splicing station 110, the web of base material 104 is transported in the web longitudinal direction WD so that it may enter the nip roll 112. The nip rollers 112 are configured to facilitate controlling the speed at which the web of base material 104 is conveyed through the production system 100. In one embodiment, the nip roller 112 includes at least two adjacent rollers 114 having a gap therebetween defining a nip. The nip is sized such that the web of base material 104 is pressed against each of the two adjacent rollers 114, with the pressure being sufficiently high to allow the friction energy of the rollers to move the web of base material 104, but the pressure is also sufficiently low to avoid any significant deformation or damage to the web of base material 104. In some suitable embodiments, the pressure exerted by the at least two adjacent rollers 114 on the web of base material 104 is set to a force in the range of 0 to 210 pounds across the cross-web span Sw of the web of base material 104 (i.e., the edge-to-edge distance of the web in the cross-web direction XWD) (fig. 6, 8A), such as a force of 0 pounds, 5 pounds, 10 pounds, 15 pounds, 20 pounds, 25 pounds, 30 pounds, 35 pounds, 40 pounds, 45 pounds, 50 pounds, 55 pounds, 60 pounds, 65 pounds, 70 pounds, 75 pounds, 80 pounds, 85 pounds, 90 pounds, 95 pounds, 100 pounds, 110 pounds, 120 pounds, 130 pounds, 140 pounds, 150 pounds, 160 pounds, 170 pounds, 180 pounds, 190 pounds, 200 pounds, or 210 pounds.

In one suitable embodiment, at least one of the adjacent rollers 114 is a flexible roller, which may be a high friction roller driven by a motor, and the other of the adjacent rollers 114 is a low friction passive roller. The flexible roll may have at least one outer surface made of rubber or polymer that is capable of providing sufficient grip on the web of base material 104 to provide a pushing or pulling force on the web of base material 104 to transport it through the production system 100. In one embodiment, at least one of the adjacent rollers 114 is a steel roller having a diameter of about 3.8 inches, such as 3.863 inches (98.12 millimeters). In another embodiment, at least one of the adjacent rollers 114 is a rubber roller having a diameter of about 2.5 inches, such as 2.54 inches (64.51 millimeters). In yet another embodiment, one or more of the adjacent rollers 114 include rubber rings placed thereon that are adjustable to be placed anywhere along the width of the rollers, each ring having an outer diameter of about 3.90 inches (99.06 mm). It should be understood that the diameter of the roller may be less than or greater than such an amount, so long as the roller functions as described herein. In one embodiment, rubber rings are placed on the rollers to contact the web of base material 104 at its continuous outer edges to drive the web of base material 104 in the web travel direction WD. Thus, the speed of the web of base material 104 is controlled by controlling the rotational speed of the high friction roller via the user interface 116. In other embodiments, each of the adjacent rollers 114 may be made of any high friction or low friction material that allows the production system 100 to function as described herein. It should be appreciated that one or more of the adjacent rollers 114 may be connected to a motor (not shown) for controlling the speed of the web of base material 104 through the nip. The production system 100 may include one or more additional nip rollers 122, 132 to facilitate controlling the speed at which the base material 104 is conveyed through the production system 100, which may be controlled via the user interface 116. When multiple nip rollers 112, 122, and 132 are used, each of the nip rollers 112, 122, and 132 may be set to the same speed by the user interface 116 such that the web of base material 104 is smoothly conveyed through the production system 100.

The production system 100 may also include dancer 118. As shown in fig. 2, the dancer 118 is shown to include a pair of rollers that are spaced apart from each other but are connected about a central axis between the pair of rollers of the dancer 118. The pair of dancer rollers 118 may rotate about a central axis to passively adjust the tension on the web of base material 104. For example, if the tension on the web of base material 104 exceeds a predetermined threshold, the pair of rolls of dancer roll 118 rotate about a central axis to reduce the tension on the web. Thus, the dancer 118 may use the mass of the dancer 118 alone (e.g., the mass of one or both of a pair of rollers), a spring, torsion bar, or other biasing/tensioning device that may be adjusted or controlled by the user through the user interface 116 to ensure that proper tension is always maintained on the web of base material 104. In one embodiment, the mass of dancer 118 and the inertia of dancer 118 are reduced or minimized, for example, by using hollow rollers made of aluminum, to allow web tension at or below 500 grams force. In other embodiments, the rolls of dancer 118 are made of other lightweight materials, such as carbon fiber, aluminum alloys, magnesium, other lightweight metals and metal alloys, fiberglass, or any other suitable material that allows a mass low enough to provide a web tension equal to or below 500 grams force. In yet another embodiment, the rolls of dancer 118 are balanced to allow a tension in the web of base material 104 of 250 grams force or less.

Production system 100 includes one or more laser systems 120a, 120b, and 120c. The embodiment shown in FIG. 2 includes three laser systems 120a-c, but it should be understood that any number of laser systems 120 may be used to allow production system 100 to function as described herein. The laser systems 120a-c are further described with reference to fig. 3. In one suitable embodiment, at least one of the laser systems 120a-c includes a laser device 300, the laser device 300 configured to emit a laser beam 302 toward a cutting plenum 304. In the illustrated embodiment, the cutting plenum 304 includes a suction cup 306 and a vacuum device 308. The details of the suction cup 306 are best shown in fig. 4 and 13, and are further described below. In one suitable embodiment, adjacent to the laser system 120 are one or more inspection devices 310, 312, which may be visual inspection devices, such as cameras or any other suitable inspection system that allows the production system 100 to function as further described herein.

The exemplary production system 100 shown in fig. 2 includes one or more cleaning stations, such as a brushing station 124 and an air knife 126. Each cleaning station is configured to remove or otherwise facilitate removal of debris (not shown) from the web of base material 104, as further described herein.

The production system 100 of fig. 2 includes an inspection station 128 for identifying defects and an associated defect marking system 130 for marking the web of base material 104 to identify the location of the identified defects, as described below.

In one suitable embodiment, the web of base material 104 is rewound by a rewind roll 134 with the web of onsert material 138 unwound by an onsert roll 136 to form a roll of electrodes 140, with electrode layers separated by the web of onsert material 138. In some embodiments, the web of base material 104 may be rewound by the rewind roll 134 without the web of onsert material 138.

It should be noted that the series of nip rollers 112, 122, and 132, idler rollers 108a-x, and dancer roller 118 may be collectively referred to as a conveyor system for conveying a web of base material 104 through the production system 100. As used herein, conveyance of the conveyance system or web of base material 104 refers to the intended movement of the web of base material 104 through the production system 100 in the web longitudinal direction WD.

Referring to fig. 5, the web of base material 104 may be any material suitable for producing an electrode member for use in a battery described herein. For example, the web of base material 104 may be an electrically insulating separator material 500, an anode material 502, or a cathode material 504. In one suitable embodiment, the web of base material 104 is an electrically insulating and ion permeable polymer woven material suitable for use as a separator in a secondary battery.

In another suitable embodiment, the web of base material 104 is a web of anode material 502, which may include an anode current collector layer 506 and an anode active material layer 508. In one embodiment, anode current collector layer 506 comprises a conductive metal, such as copper, a copper alloy, or any other material suitable as an anode current collector layer. The anode active material layer 508 may be formed as a first layer on a first surface of the anode current collector layer 506 and a second layer on an opposite second surface of the anode current collector layer 506. In another embodiment, the anode current collector layer 506 and the anode active material layer 508 may be intermixed. The first surface and the opposing second surface may be referred to as the major surface or the front and back surfaces of the web of base material 104. As used herein, a major surface refers to a surface defined by a plane formed by the length of the web of base material 104 in the web longitudinal direction WD and the span of the web of base material 104 in the cross-web direction XWD.

In general, when the web of base material 104 is a web of anode material 502, the (each) anode active material layer 508 will each have a thickness of at least about 10 μm. For example, in one embodiment, the thickness of each of the (each) anode active material layer 508 will be at least about 40 μm. As a further example, in one such embodiment, the (each) anode active material layer 508 will each have a thickness of at least about 80 μm. As a further example, in one such embodiment, the (each) anode active material layer 508 will have a thickness of at least about 120 μm. However, typically, the (each) anode active material layer 508 will have a thickness of less than about 60 μm or even less than about 30 μm.

Exemplary anode active materials for use as anode active material layer 508 include carbon materials such as graphite, soft or hard carbon, or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of metals, semi-metals, alloys, oxides, nitrides, and compounds capable of intercalating or alloying with lithium. Specific examples of metals or semi-metals that can make up anode material 502 include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon/carbon composites, silicon/graphite blends, silicon oxides (SiO _x ) Porous silicon, intermetallic silicon alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, and mixtures thereof. In one exemplary embodiment, the anode active material layer 508 includes aluminum, tin, or silicon, or an oxide thereof, a nitride thereof, a fluoride thereof, or other alloys thereof. In another exemplary embodiment, the anode active material layer 508 includes silicon or an alloy thereof or an oxide thereof.

In one embodiment, the anode active material layer 508 is microstructured to provide a significant void volume fraction to accommodate volume expansion and contraction as lithium ions (or other carrier ions) are incorporated into the anode active material layer 508 or leave the anode active material layer 508 during charge and discharge. Typically, the void volume fraction of the (each) anode active material layer 508 is at least 0.1. But typically, the void volume fraction of the (each) anode active material layer 508 is not greater than 0.8. For example, in one embodiment, the void volume fraction of the (each) anode active material layer 508 is about 0.15 to about 0.75. As another example, in one embodiment, the void volume fraction of the (each) anode active material layer 508 is about 0.2 to about 0.7. As another example, in one embodiment, the void volume fraction of the (each) anode active material layer 508 is about 0.25 to about 0.6.

Depending on the composition of the microstructured anode active material layer 508 and the method of forming the same, the microstructured anode active material layer 508 may include a macroporous material layer, a microporous material layer, or a mesoporous material layer, or a combination thereof, such as a combination of micropores and mesopores, or a combination of mesopores and macropores. Microporous materials are generally characterized by pore sizes of less than 10nm, wall sizes of less than 10nm, pore depths of 1-50 microns, and pore morphologies that are generally characterized by "spongy" and irregular appearance, non-smooth walls, and branched pores. Mesoporous materials are typically characterized by a pore size of 10-50 nanometers, a wall size of 10-50 nanometers, a pore depth of 1-100 microns, and a pore morphology typically characterized by well-defined branched or dendritic pores. Typical features of macroporous materials are pore sizes greater than 50 nanometers, wall sizes greater than 50 nanometers, pore depths of 1-500 microns, and pore morphologies that can be varied, straight, branched, or dendritic, and smooth or rough walls. Further, the void volume may comprise open voids or closed voids, or a combination thereof. In one embodiment, the void volume includes open voids, i.e., the anode active material layer 508 contains voids having openings in the side surfaces of the anode active material layer 508 through which lithium ions (or other carrier ions) can enter or leave the anode active material layer 508; for example, lithium ions may enter the anode active material layer 508 through the void openings after leaving the cathode active material layer 512. In another embodiment, the void volume includes closed voids, i.e., the anode active material layer 508 contains voids that are closed within the anode active material layer 508. In general, open voids may provide a greater interfacial surface area for carrier ions, while closed voids tend to be less sensitive to solid electrolyte interfaces, while each void provides room for expansion of anode active material layer 508 as carrier ions enter. Thus, in certain embodiments, it is preferred that the anode active material layer 508 include a combination of open and closed voids.

In one embodiment, the anode active material layer 508 includes porous aluminum, tin, or silicon or an alloy thereof, an oxide thereof, or a nitride thereof. The porous silicon layer may be formed, for example, by anodic oxidation, by etching (e.g., by depositing a noble metal such as gold, platinum, silver, or gold/palladium on a monocrystalline silicon surface, and etching the surface with a mixture of hydrofluoric acid and hydrogen peroxide), or by other methods known in the art such as patterned chemical etching. Further, the porous anode active material layer 508 will typically have a porosity of at least about 0.1 but less than 0.8 and a thickness of about 1 micron to about 100 microns. For example, in one embodiment, the anode active material layer 508 comprises porous silicon, has a thickness of about 5 microns to about 100 microns, and has a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material layer 508 includes porous silicon, has a thickness of about 10 microns to about 80 microns, and has a porosity of about 0.15 to about 0.7. As a further example, in one such embodiment, the anode active material layer 508 includes porous silicon, has a thickness of about 20 microns to about 50 microns, and has a porosity of about 0.25 to about 0.6. As a further example, in one embodiment, the anode active material layer 508 comprises a porous silicon alloy (e.g., nickel silicide), has a thickness of about 5 microns to about 100 microns, and has a porosity of about 0.15 to about 0.75.

In another embodiment, the anode active material layer 508 includes fibers of aluminum, tin, or silicon, or alloys thereof. The individual fibers may have a diameter (thickness dimension) of about 5nm to about 10,000nm, with a length generally corresponding to the thickness of the anode active material layer 508. Silicon fibers (nanowires) may be formed by, for example, chemical vapor deposition or other techniques known in the art, such as gas-liquid-solid (VLS) growth and solid-liquid-solid (SLS) growth. In addition, the anode active material layer 508 will typically have a porosity of at least about 0.1 but less than 0.8, and a thickness of about 1 micron to about 200 microns. For example, in one embodiment, the anode active material layer 508 includes silicon nanowires having a thickness of about 5 microns to about 100 microns and having a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material layer 508 includes silicon nanowires having a thickness of about 10 microns to about 80 microns and having a porosity of about 0.15 to about 0.7. As a further example, in one such embodiment, the anode active material layer 508 includes silicon nanowires having a thickness of about 20 microns to about 50 microns and having a porosity of about 0.25 to about 0.6. As a further example, in one embodiment, the anode active material layer 508 includes nanowires of a silicon alloy (e.g., nickel silicide), has a thickness of about 5 microns to about 100 microns, and has a porosity of about 0.15 to about 0.75.

Typically, the conductivity of the anode current collector layer 506 will be at least about 10 ³ Siemens per centimeter (S/cm). For example, in one such embodiment, the anode current collector layer 506 will have a thickness of at least about 10 ⁴ Conductivity of S/cm. As a further example, in one such embodiment, anode current collector layer 506 will have a thickness of at least about 10 ⁵ Conductivity of S/cm. Exemplary conductive materials suitable for use as anode current collector layer 506 include metals such as copper, nickel, cobalt, titanium, and tungsten, and alloys thereof.

Referring again to fig. 5, in another suitable embodiment, the web of base material 104 is a web of cathode material 504, which may include a cathode current collector layer 510 and a cathode active material layer 512. The cathode current collector layer 510 of the cathode material 504 may include aluminum, aluminum alloy, titanium, or any other material suitable for use as the cathode current collector layer 510. The cathode active material layer 512 may be formed as a first layer on a first surface of the cathode current collector layer 510 and a second layer on an opposite second surface of the cathode current collector layer 510. The cathode active material layer 512 may be coated on one side or both sides of the cathode current collector layer 510. Similarly, the cathode active material layer 512 may be coated on one or both major surfaces of the cathode current collector layer 510. In another embodiment, the cathode current collector layer 510 may be mixed with the cathode active material layer 512.

In general, when the web of base material 104 is a web of cathode material 504, the thickness of the (each) cathode active material layer 512 will be at least about 20 μm. For example, in one embodiment, the thickness of the (each) cathode active material layer 512 is at least about 40 μm. As a further example, in one such embodiment, the (each) cathode active material layer 512 will have a thickness of at least about 60 μm. As a further example, in one such embodiment, the (each) cathode active material layer 512 will have a thickness of at least about 100 μm. Typically, however, the (each) cathode active material layer 512 will have a thickness of less than about 90 μm or even less than about 70 μm.

Exemplary cathode active materials include any of a variety of cathode active materials. For example, for a lithium ion battery, the cathode active material layer 512 may include a cathode active material selected from the group consisting of transition metal oxides, transition metal sulfides, transition metal nitrides, lithium transition metal oxides, lithium transition metal sulfides, and lithium transition metal nitrides, which may be selectively used. The transition metal elements of these transition metal oxides, transition metal sulfides and transition metal nitrides may include metal elements having a d-shell layer or an f-shell layer. Specific examples of such metallic elements are Sc, Y, lanthanoid, actinoid, ti, zr, hf, V, nb, ta, cr, mo, W, mn, tc, re, fe, ru, os, co, rh, ir, ni, pb, pt, cu, ag, and Au. Additional cathode active materials include LiCoO ₂ 、LiNi _0.5 Mn _1.5 O ₄ 、Li(Ni _x Co _y Al _z )O ₂ 、LiFePO ₄ 、Li ₂ MnO ₄ 、V ₂ O ₅ Molybdenum oxysulfide, phosphate, silicate, vanadate, sulfur compound, oxygen (air), li (Ni) _x Mn _y Co _z )O ₂ And combinations thereof.

Typically, the cathode current conductor layer 510 has an electrical conductivity of at least about 10 ³ S/cm. For example, inIn one such embodiment, the cathode current conductor layer 510 will have at least about 10 ⁴ Conductivity of S/cm. As a further example, in one such embodiment, cathode current conductor layer 510 will have a thickness of at least about 10 ⁵ Conductivity of S/cm. Exemplary cathode current conductor layer 510 includes metals such as aluminum, nickel, cobalt, titanium, and tungsten, and alloys thereof.

Referring again to fig. 5, in another suitable embodiment, the web of base material 104 is a web of electrically insulating but ion permeable separator material. The electrically insulating separator material 500 is adapted to electrically insulate each member of the anode group from each member of the cathode group of the secondary battery. The electrically insulating separator material 500 generally comprises a microporous separator material that is permeable to non-aqueous electrolytes; for example, in one embodiment, the microporous separator material comprises a diameter of at leastMore typically at about +.>About 25% to about 75%, more typically in the range of about 35-55%.

In general, when the web of base material 104 is a web of electrically insulating separator material 500, the thickness of electrically insulating separator material 500 will be at least about 4 μm. For example, in one embodiment, the thickness of the electrically insulating separator material 500 will be at least about 8 μm. As a further example, in one such embodiment, the electrically insulating separator material 500 will have a thickness of at least about 12 μm. As a further example, in one such embodiment, the electrically insulating separator material 500 will have a thickness of at least about 15 μm. Typically, however, the electrically insulating separator material 500 will have a thickness of less than about 12 μm or even less than about 10 μm.

In one embodiment, the microporous separator material comprises a particulate material and a binder and has a porosity (void fraction) of at least about 20% by volume. The pore of the microporous separator material has a diameter of at leastUsually about->To the point ofWithin a range of (2). The microporous separator material will typically have a porosity of less than about 75% by volume. In one embodiment, the microporous separator material will have a porosity (void fraction) of at least about 25% by volume. In one embodiment, the microporous separator material will have a porosity of about 35-55% by volume.

The binder for the microporous separator material may be selected from a variety of inorganic materials or polymeric materials. For example, in one embodiment, the binder is an organic material selected from the group consisting of silicates, phosphates, aluminates, aluminosilicates, and hydroxides such as magnesium hydroxide, calcium hydroxide, and the like. For example, in one embodiment, the binder is a fluoropolymer derived from monomers comprising vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, and the like. In another embodiment, the binder is a polyolefin, such as polyethylene, polypropylene, or polybutylene, having any of a range of any of a variety of different molecular weights and densities. In another embodiment, the binder is selected from ethylene-diene-propylene terpolymers, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate. In another embodiment, the binder is selected from the group consisting of methylcellulose, carboxymethylcellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, and polyethylene oxide. In another embodiment, the binder is selected from the group consisting of acrylates, styrenes, epoxies, and polysiloxanes. In another embodiment, the adhesive is a copolymer or blend of two or more of the above polymers.

The particulate material comprised by the microporous separator material may also be selected from a variety of materials. Typically, such materials have relatively low electron conductivity and dissociation at operating temperaturesSub-conductivity, and does not corrode at the operating voltage of the battery electrode or current collector that contacts the microporous separator material. For example, in one embodiment, the particulate material has a conductivity of less than 1×10 for carrier ions (e.g., lithium) ^-4 S/cm. As a further example, in one embodiment, the particulate material has a conductivity of less than 1X 10 for carrier ions ^-5 S/cm. As a further example, in one embodiment, the particulate material has a conductivity of less than 1X 10 for carrier ions ^-6 S/cm. Exemplary particulate materials include particulate polyethylene, polypropylene, tiO ₂ -polymer composites, silica aerogels, fumed silica, silica gels, silica hydrogels, silica xerogels, silica sols, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, magnesium carbonate, or combinations thereof. For example, in one embodiment, the particulate material comprises a particulate oxide or nitride, such as TiO ₂ 、SiO ₂ 、Al ₂ O ₃ 、GeO ₂ 、B ₂ O ₃ 、Bi ₂ O ₃ 、BaO、ZnO、ZrO ₂ 、BN、Si ₃ N ₄ 、Ge ₃ N ₄ . See, e.g., p.arora and j.zhang, "Battery Separators" Chemical Reviews 2004, 104, 4419-4462. In one embodiment, the particulate material will have an average particle size of about 20 nanometers to 2 microns, more typically 200 nanometers to 1.5 microns. In one embodiment, the particulate material will have an average particle size of about 500 nanometers to 1 micrometer.

In an alternative embodiment, the particulate material contained in the microporous separator material may be combined by sintering, bonding, curing, etc. techniques while maintaining the desired void fraction for electrolyte ingress to provide ionic conductivity for operation of the cell.

In the assembled energy storage device, the microporous separator material is impregnated with a nonaqueous electrolyte suitable for use as a secondary battery electrolyte. Typically, the nonaqueous electrolyte comprises lithium salts and/or mixtures of salts dissolved in an organic solvent and/or solvent mixture. Exemplary lithium salts include: inorganic lithium saltFor example LiClO ₄ 、LiBF ₄ 、LiPF ₆ 、LiAsF ₆ LiCl and LiBr; and organolithium salts, e.g. LiB (C) ₆ H ₅ ) ₄ 、LiN(SO ₂ CF ₃ ) ₂ 、LiN(SO ₂ CF ₃ ) ₃ 、LiNSO ₂ CF ₃ 、LiNSO ₂ CF ₅ 、LiNSO ₂ C ₄ F ₉ 、LiNSO ₂ C5F ₁₁ 、LiNSO ₂ C ₆ F ₁₃ And LiNSO ₂ C ₇ F ₁₅ . Exemplary organic solvents that dissolve the lithium salt include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of the cyclic esters include propylene carbonate, butylene carbonate, gamma-butyrolactone, vinylene carbonate, 2-methyl-gamma-butyrolactone, acetyl-gamma-butyrolactone, and gamma-valerolactone. Specific examples of the chain ester include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dipropyl carbonate, methylethyl carbonate, methylbutyl carbonate, methylpropyl carbonate, ethylbutyl carbonate, ethylpropyl carbonate, butylpropyl carbonate, alkyl propionate, dialkyl malonate and alkyl acetate. Specific examples of the cyclic ether include tetrahydrofuran, alkyl tetrahydrofuran, dialkyl tetrahydrofuran, alkoxy tetrahydrofuran, dialkoxy tetrahydrofuran, 1, 3-dioxolane, alkyl-1, 3-dioxolane, and 1, 4-dioxolane. Specific examples of the chain ether include 1, 2-dimethoxyethane, 1, 2-diethoxyethane, diethyl ether, ethylene glycol dialkyl ether, diethylene glycol dialkyl ether, triethylene glycol dialkyl ether and tetraethylene glycol dialkyl ether.

In other embodiments, the web of base material 104 may be any material suitable for producing an electrode member for use in a solid secondary battery, such as the material described in U.S. patent No. 9,553,332 issued 24, 2017, which is incorporated herein by reference in its entirety. For example, in some embodiments, the web of base material 104 may include an electrode current collector material, such as a negative electrode current collector material or a positive electrode current collector material. In some embodiments, the electrode current collector material may include copper, nickel-coated copper, iron-coated copper, copper-coated aluminum, titanium, stainless steel, or other materials known to be non-alloyed with lithium and configured to function as an anode current collector. In another embodiment, the web of base material 104 is a positive current collector material including aluminum, aluminum foil, carbon coated aluminum foil. In such embodiments, the electrode current collector material may be a metal coating, rather than a foil, produced by standard means, such as electroplating, electroless plating, PVD, metal nanoparticle sintering, and/or sol-gel with post-reduction.

In another embodiment, such as for solid secondary batteries, the web of base material 104 may comprise a solid electrolyte material, such as those described in the above-referenced U.S. patent No. 9,553,332. In this embodiment, the web of base material 104 may include an electrical conductivity greater than 10 ^-5 S/cm of a fast lithium ion conductor, such as garnet, liPON, anti-perovskite, LISICON, thio LISICON, sulfide, oxysulfide, polymer, composite polymer, ionic liquid, gel or organic liquid. The thickness of the electrolyte ranges from about 0.1 μm to about 40 μm, but includes variations. In some examples, the electrolyte thickness is 25 μm, i.e., 25 microns. In some examples, the electrolyte thickness is 25 μm or less, i.e., 25 μm or less.

In another embodiment, such as for a solid secondary battery, the web of base material 104 may comprise a catholyte material, such as the catholyte material described in U.S. patent No. 9,553,332 referenced above. In this embodiment, the web of base material 104 includes a catholyte material comprising or a lithium, silicon, phosphorus and sulfur ("LGPS") containing material, each of which is configured in a polycrystalline or amorphous state. In this embodiment, the catholyte material has an ionic conductivity greater than 10 ^-4 S/cm, preferably greater than 10 ^-3 S/cm. In one embodiment, the particle size of the catholyte material is smaller than the particle size of the active region. For example, in some embodiments, the median catholyte particle diameter is 1/3 times or less the median active particle diameter. The catholyte material may alternatively be configured as a core-shell structure as a coating around the cathode active material. In another variation, the catholyte material may be configured as a nanorod or nanowire. At the position of In this embodiment, the web of base material 104 may also include cathode electron conducting substances such as carbon, activated carbon, carbon black, carbon fibers, carbon nanotubes, graphite, graphene, fullerenes, metal nanowires, super P, and other materials known in the art. The cathode region also includes a binder material to improve the adhesion of the cathode to the substrate and the cohesion of the cathode to itself during cycling. In one embodiment, the catholyte material has oxygen species disposed within the LGPS or LSPS containing material. In another embodiment, the ratio of oxygen species to sulfur species is 1:2 or less to form an LGPSO material or LSPSO material. In one example, the oxygen species is less than 20% of the LGPSO material.

In various other embodiments, the web of base material 104 may be suitable for use in producing electrode components for use in solid secondary batteries, such as those described in U.S. patent No. 9,553,33, referenced above, wherein the catholyte material is characterized as a solid. In this embodiment, the catholyte material has a substantially fixed compound structure that behaves like a solid rather than a fluid. In one embodiment, the solid catholyte material is fabricated by Physical Vapor Deposition (PVD), chemical Vapor Deposition (CVD), atomic Layer Deposition (ALD), and solid state reaction of powders, mechanical milling of powders, solution synthesis, vaporization, or any combination thereof. In another embodiment, the catholyte material is mixed with the active material in a mixer or mill, or in a physical vapor deposition of a different configuration, optionally with carbon, and applied to the substrate by gravure printing, comma coating, meyer rod coating, knife coating, nip extrusion coating, or by conventional techniques. In another embodiment, the catholyte material is coated directly onto the cathode active material by vapor phase growth, mechanical fusion, liquid phase growth, deposition on particles in a fluidized bed or rotating reactor, or a combination thereof, or the like. In another embodiment, the web of base material 104 includes a polymeric material that includes lithium species. The polymeric material may be formed overlying the catholyte material. In some embodiments, the polymeric material is polyacrylonitrile, polyethylene oxide, pvDF-HFP, rubber such as butadiene rubber, styrene butadiene rubber, and the like.

In one embodiment, the web of base material 104 may have a tape layer (not shown) adhered to one or both surfaces of the anode active material layer 508 or the cathode active material layer 512, respectively. After ablation and cutting (as described below) to remove unwanted material or debris, the adhesive layer may then be removed.

Embodiments of the laser systems 120a-c are further described with reference to fig. 2-6. The web of base material 104 enters the laser system 120 in the web longitudinal direction WD. In one embodiment, the web of base material 104 enters the laser system 120a in a first state 400 that has not been ablated or cut. Thus, the web of base material 104 in the first state 400 should be substantially free of defects or alterations from the original state. The web of base material 104 passes over the suction cup 306, the suction cup 306 including a plurality of vacuum holes 406. The vacuum holes 406 are in fluid communication with the vacuum device 308 to create a vacuum pressure on the web of base material 104 passing over the vacuum holes 406. The vacuum holes 406 may be staggered and/or chamfered to allow the web of base material 104 to more easily pass over them without obstruction. The cross-sectional area of the aperture must be small enough to prevent the web of base material 104 from being sucked into it, but large enough to allow proper air flow from the vacuum device to pass through it. The vacuum pressure helps to maintain the web of base material 104 in a substantially flat/planar state as it is conveyed through the suction cups 306. In some suitable embodiments, the laser system 120 is sensitive to focus, and in such embodiments it is critical to maintain the web of base material 104 at a substantially constant distance from the laser output 313, for example +/-100 microns from a predetermined location, to ensure that it is in focus when the laser beam 302 contacts the web of base material 104 during cutting or ablation. Thus, the vacuum pressure through the vacuum holes 406 may be monitored and adjusted in real time, such as through the user interface 116, to ensure that the web of base material 104 remains substantially flat on the suction cups 306 and does not lift or bend during processing. The cross-sectional shape of the vacuum holes 406 may be circular, square, rectangular, oval, or any other shape that allows the suction cups 306 to function as described herein.

As shown in fig. 4, the suction cup 306 (e.g., a bearing surface) includes an opening 410 defined by an upstream edge 412 and a downstream edge 414. The illustrated suction cup 306 includes a chamfer 416 on the downstream edge 414. In this embodiment, the chamfer 416 facilitates the web of base material 104 to pass the downstream edge 414 without catching or retarding the web of base material 104 on the downstream edge 414. The angle α of the chamfer 416 may be in the range of 1 degree to 90 degrees, such as 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, or any other angle that allows the chamfer 416 to function as described herein. For example, in the illustrated embodiment, the angle α is approximately 25 degrees. It has been found that performance is improved if the angle α of the chamfer 416 is greater than the deflection of the web of base material 104 passing over the chamfer 416. The upper edge 418 of the chamfer 416 may be rounded to provide a smooth transition from the chamfer 416 to the surface of the suction cup 306.

In one suitable embodiment, the suction cup 306 is made of aluminum. However, the suction cup 306 may be formed from an aluminum alloy, a composite material, a metal or metal alloy, or any other suitable material that allows the suction cup 306 to function as described herein. In one embodiment, the material of the suction cups 306, such as aluminum, helps to dissipate heat from the web during laser processing.

In one suitable embodiment, the web of base material 104 is first ablated by laser beam 302 (FIG. 3) to create ablated portion 404 (FIG. 4) in the web of base material 104, which is in second state 402 after ablation by laser beam 302. In one embodiment, the web of base material 104 is anode material 502, and ablative portion 404 removes anode active material layer 508 to expose anode current collector layer 506 (fig. 5). In another embodiment, the web of base material 104 is cathode material 504, and ablative portion 404 removes cathode active material layer 512 to expose cathode current conductor layer 510. In one embodiment, the ablation portion 404 is configured as an electrode tab (adapted to electrically connect the cathode current collector layer 510 and the anode current collector layer 506 to the positive and negative terminals, respectively, of the secondary battery). When using laser system 120a to create ablation 404 in the web of base material 104, the power of laser beam 302 is set to a level that is capable of substantially completely or completely removing the coating, but without damaging or cutting through the current collector layer. In use, the laser beam 302 is controlled, for example by the user interface 116, to create the ablation portion 404 as the web of base material 104 moves and is conveyed in the web machine direction WD. As shown in fig. 5, ablations 404 are formed on each side of the base material 104. In one embodiment, after ablation portion 404 is fabricated, laser system 120a forms fiducial feature 602, as further described herein. In another embodiment, a plurality of laser systems 120a may be used to each ablate a portion of the base material 104 to each create one or more ablated sections 404, thereby increasing the throughput of the production system 100.

With further reference to fig. 2, 3 and 4, at another stage of the production system, the web of material 104 is transported in the web longitudinal direction WD towards the cutting region 408 of the laser system 120 a. The cutting region 408 includes an opening 410 of the suction cup 306. In one embodiment, the opening 410 is in fluid communication with the vacuum device 308 to create a vacuum pressure on the web of base material 104 passing over the opening 410. In one suitable embodiment, the opening 410 is wider in the cross-web direction XWD than the web of the base material 104 such that the entire width of the web of the base material 104 in the cross-web direction XWD is suspended above the opening 410. In one embodiment, there may be a second vacuum device configured to balance the pressure on the web of base material 104 against the suction cups 306. In this embodiment, the equalization of pressure helps to maintain the web of base material 104 in a substantially flat/planar state and at a consistent height as it passes over opening 410, which helps to keep laser beam 302 focused on the web of base material 104. In one embodiment, a carrier web may be used to support the web of base material 104. In some embodiments, the carrier web is removably attached to the web of base material 104 using a low tack adhesive or electrostatic pins. In such embodiments, the attachment has sufficient adhesion to remain attached to the web of base material 104 during processing, but may be removed without damage to the web of base material 104. In one embodiment, the carrier web is a material that does not absorb the laser wavelength used during processing of the web of base material 104 so that the carrier web is not cut through, gasified or ablated and thus can be reused on other webs of base material 104.

The laser system 120a is configured to cut one or more patterns (e.g., individual electrode patterns 800 (fig. 8), which may also be referred to as electrode tear patterns or weakened tear patterns) to score each member of a group of electrode structures in the web of base material 104 as the web of base material 104 is positioned over the opening 410. In one embodiment, there may be a plurality of openings 410 for which one or more electrode patterns 800 are cut while the web of base material 104 is over a corresponding one of the openings. Referring to fig. 6, the pattern may include one or more longitudinal edge cuts 600 that define the longitudinal edges of the electrodes in the cross-web direction XWD. The longitudinal edge cuts 600 are cut using the laser beam 302 to cut the web of the base material 104 in the cross-web direction XWD while the web of the base material 104 is conveyed in the cross-web direction WD. The cross-web direction XWD is orthogonal to the cross-web direction WD. It should be noted that in one embodiment, in order to create a longitudinal edge cut 600 that is substantially perpendicular to the web longitudinal direction WD, the laser beam 302 must be controlled to travel at an angle relative to the web longitudinal direction WD to account for movement of the web of base material 104 in the web longitudinal direction WD. For example, as the web of base material 104 moves in the web longitudinal direction WD, the path of the laser beam 302 is projected onto the web of base material 104 at the initial cutting location 604 and then synchronized with the movement of the web of base material 104 in the web direction. Thus, the path of the laser beam 302 is controlled to travel in both the cross-web direction XWD and the cross-web direction WD until reaching the end cutting position 606 to create the longitudinal edge cut 600. In this embodiment, a compensation factor is applied to the path of the laser beam 302 to allow cutting in the cross-web direction XWD while the web of base material 104 is traveling continuously in the cross-web direction WD. It should be appreciated that the angle at which the laser beam 302 travels varies depending on the speed of the web of base material 104 in the web longitudinal direction WD. In another embodiment, the web of base material 104 is temporarily stopped during the laser machining operation, and thus, the path of the laser beam 302 need not take into account the traveling motion of the web of base material 104 in the web longitudinal direction WD. Such an embodiment may be referred to as a step-and-repeat process. During laser processing, one or more of the laser systems 120a-c use repeated alignment features, such as the fiducial feature 602, to adjust/align the laser beam 302 during laser processing operations, such as to compensate for possible variations in positioning of the web of base material 104.

It should be appreciated that while the laser machining operations described herein may define the longitudinal edge cuts 600 along the cross-web direction XWD such that the repeating pattern of the single electrode pattern 800 is aligned along the cross-web direction XWD, in other embodiments, the laser machining operations described herein may be controlled such that the longitudinal edge cuts 600 and all associated cuts, perforations, and ablations are each oriented vertically. For example, the longitudinal edge cuts 600 may be aligned in the web longitudinal direction WD such that groups of individual electrode patterns 800 are aligned in the web longitudinal direction WD, rather than in the web cross-direction XWD.

In one embodiment, the laser system 120a cuts tie bars 614 between one or more individual electrode patterns 800. Tie bars 614 may be used to scribe between groups of individual electrode patterns 800. For example, in the embodiment shown in fig. 6, tie bars 614 are cut between groups of five individual electrode patterns 800. However, in other embodiments, the tie bars 614 may be included after any number of individual electrode patterns 800, or not present at all. Tie bars 614 are defined by upstream tie bar edge cuts 616 and downstream tie bar edge cuts 618, respectively. In some embodiments, the tie bars 614 are sized to provide additional structural rigidity to the web of base material 104 during processing.

Furthermore, in one suitable embodiment, the laser system 120a cuts one or more repeated registration features, such as a plurality of fiducial features 602, in the web of base material 104. In one embodiment, the fiducial feature 602 is a fiducial via. The fiducial features 602 are cut at known locations on the web of base material 104. The fiducial feature 602 is shown in fig. 6 as circular, but may be rectangular as shown in fig. 8, or any size or shape that allows the production system 100 to function as described herein. The fiducial feature 602 is tracked by one or more visual inspection devices 310, 312 that measure the position and travel speed of the fiducial feature 602. The measurement of the fiducial features 602 is then used to precisely allow the patterns on the web of base material 104 to be aligned back and forth in the web longitudinal direction WD and the web transverse direction XWD. The laser system 120a may also cut a plurality of draw holes 612, the draw holes 612 may be used to align the web of base material 104, or may be used as holes for engagement with gears 1210 (fig. 12) for positioning and tension control of the web of base material 104. The draw holes 612 may be circular, square, or any other shape that allows the production system 100 to function as described herein. In other suitable embodiments, the web of base material 104 has a plurality of draw holes 612 and/or fiducial features 602 pre-cut therein before being unwound and conveyed through the production system 100. In one embodiment, there is a one-to-one ratio of the fiducial features 602 to the individual electrode patterns 800. In other embodiments, there may be two or more fiducial features 602 for each individual electrode pattern 800.

Referring to fig. 2 and 6, in one suitable embodiment, the laser system 120a cuts the first and second perforations 608, 610 in the web of base material 104 as part of a single electrode pattern 800. The first perforation 608 may also be referred to as an "outer perforation" because it is located outside of the single electrode pattern 800 in the cross-web direction XWD, and the second perforation 610 may also be referred to as an "inner perforation" because it is located inside of the outer perforation 608 in the cross-web direction XWD. The perforations 608, 610 are best shown in fig. 7, which is an enlarged view of a portion 613 (fig. 5) of the web of base material 104. The first perforation 608 is formed by laser cutting using the laser beam 302 while the web of base material 104 is over the opening 410 in the suction cup 306. The first perforations 608 are formed as linear slits (e.g., through-cuts) in a direction aligned with the web longitudinal direction WD. Importantly, the first perforations 608 do not extend across the entire width We of the electrode. Instead, the outer tear strip 700 remains on the upstream and downstream edges of the first perforations 608 to ensure that the individual electrode patterns 800 remain connected to the web of base material 104.

Similarly, with further reference to fig. 6 and 7, a second perforation 610 is formed inboard (in the cross-web direction XWD) of the first perforation 608. In one suitable embodiment, the second perforations 610 are formed as a row of slits along the web longitudinal direction WD that are separated by the inner tear strip 702. In the illustrated embodiment, the second perforation 610 intersects the through-hole 704. In the illustrated embodiment, the length of inner tear strip 702 is at least twice the length of outer tear strip 700 such that the breaking force required to separate outer tear strip 700 is about half the breaking force required to separate inner tear strip 702 from the web of base material 104. In other embodiments, the ratio of the break strengths of outer tear strip 700 and inner tear strip 702 may vary, respectively, but it is preferred that the break strength of outer tear strip 700 be lower than the break strength of inner tear strip 702 such that outer tear strip 700 will break before inner tear strip 702 when a tensile or shear force is applied to the edge of the web of base material 104.

Referring to fig. 3, 4 and 6, by laser cutting the longitudinal edge cut 600, the fiducial feature 602, the first perforation 608 and the second perforation 610 over the opening 410 of the suction cup 306, debris is allowed to fall through the opening 410 and the vacuum device 308 is allowed to collect debris formed during the laser cutting process.

In one suitable embodiment, the laser system 120a is configured as a first ablation station. In this embodiment, as described above, laser system 120a forms ablated section 404 on the first surface of the web of base material 104. After exiting laser system 120a, the web of base material 104 passes over idler 108d, idler 108d inverts the web of base material 104 such that a second surface (opposite the first surface) of the web of base material 104 is positioned for processing by laser system 120b, which in this embodiment, laser system 120b is configured as a second ablation station. In this embodiment, laser system 120b is configured to use fiducial feature 602 to ensure alignment in web longitudinal direction WD and web transverse direction XWD. Thus, the laser system 120b performs a second ablation process on opposite surfaces of the web of base material 104 such that the ablated portions 404 on each surface of the web of base material 104 are aligned in the web longitudinal direction WD and the web transverse direction XWD. In one embodiment, the ablative portion 404 is configured as a current collector tab of an electrode.

In one embodiment, the laser system 120c shown in FIG. 2 is configured as a laser cutting station. In this embodiment, the laser system 120c performs laser cutting to cut, for example, the longitudinal edge cuts 600 and the first and second perforations 608, 610.

In one suitable embodiment, one or more of the laser devices 300 of the laser systems 120a-c are 20 watt fiber lasers. In various embodiments, a suitable laser device 300 of the laser system 120a-c has a laser power in the range of 10 watts to 5,000 watts, such as in the range of 10 watts to 100 watts, in the range of 100 watts to 250 watts, in the range of 250 watts to 1 kilowatt, in the range of 1 kilowatt to 2.5 kilowatts, and in the range of 2.5 kilowatts to 5 kilowatts. Suitable laser devices 300 will include laser beams 302 having wavelengths from 150 nanometers to 10.6 microns, such as from 150 nanometers to 375 nanometers, 375 nanometers to 750 nanometers, 750 nanometers to 1500 nanometers, and 1500 nanometers to 10.6 microns. In various embodiments, laser apparatus 300 will be capable of one or more laser pulse width types of continuous wave (cw), microsecond(s), nanosecond (ns), picosecond (ps), and femtosecond (fs). Any of these types of lasers may be used as the laser device 300 of the laser systems 120a-c, either alone or in combination. In other suitable embodiments, laser device 300 is any other laser capable of allowing laser systems 120a-c to perform as described herein.

In some embodiments, the web of base material 104 may include fiducial features 602, the fiducial features 602 having been machine stamped or laser cut prior to loading the web of base material 104 into the production system 100. In another suitable embodiment, the fiducial features 602 may be mechanically machine stamped after forming the ablations 404 on the first surface of the web of base material 104. In other suitable embodiments, the production system 100 may include one or more additional mechanical punches that may be used to form the longitudinal edge cuts 600 and/or one or more of the first and second perforations 608, 610.

In one embodiment, one or more of the rollers of the conveying system may not be perfectly circular, so the rollers have an eccentricity. In this case, especially if the eccentric rolls are nip rolls 112, 123, 132, the web of base material 104 may be transported in such a way that the position of the web of base material 104 advances in a different way depending on which part of the eccentric roll is in contact with the web. For example, if the eccentric roll has a radius portion that exceeds the intended radius of the roll, the web may advance farther in the web longitudinal direction WD than intended as the larger radius portion of the roll pushes/pulls the web. Also, if the eccentric roll has a portion with a reduced radius, the web may advance a smaller distance in the web longitudinal direction WD than intended. Thus, in one embodiment, the eccentric roller may be mapped to determine the radius-to-radial position. The laser systems 120a-c may then be controlled to adjust the position of the laser beam 302 based on the roller mapping to account for the eccentricity. In one embodiment, the mapping of the rollers may be stored in a memory of the user interface 116.

After exiting one or more of the laser systems 120a-c, the web of base material 104 may be transported to one or more cleaning stations, such as a brushing station 124 and an air knife 126. In one suitable embodiment, the brushing station 124 includes a brush 1000 (fig. 10 and 11) that travels in the cross-web direction XWD. The brush 1000 includes a set of bristles 1002 held by a bristle holder 1004. The brush 1000 is configured to allow bristles 1002 to gently contact the surface of the web of base material 104 and remove or remove any debris therefrom. The contact pressure of the bristles 1002 on the surface of the web of base material 104 must be low enough so that the individual electrode patterns 800 do not fracture, crack or otherwise cause defects in the individual electrode patterns 800 and keep the individual electrode patterns 800 attached to the web of base material 104. In one embodiment, the normal force between the bristles 1002 and the surface of the web of base material 104 is 0 to 2 pounds, such as 0.1 pounds, 0.2 pounds, 0.3 pounds, 0.4 pounds, 0.5 pounds, 0.6 pounds, 0.7 pounds, 0.8 pounds, 0.9 pounds, 1.0 pounds, 1.1 pounds, 1.2 pounds, 1.3 pounds, 1.4 pounds, 1.5 pounds, 1.6 pounds, 1.7 pounds, 1.8 pounds, or 2.0 pounds. In other embodiments, the normal force may be greater than 2.0 pounds.

In one embodiment, the bristles 1002 have a length of 3/4 inch (19.05 millimeters). In one embodiment, the bristles 1002 are embedded or clamped about 1/8 inch within the bristle holder 1004. The bristles 1002 may have diameters of 0.003 inch (0.076 millimeter) to 0.010 inch (0.254 millimeter), such as 0.003 inch (0.076 millimeter), 0.004 inch (0.101 millimeter), 0.005 inch (0.127 millimeter), 0.006 inch (0.152 millimeter), 0.007 inch (0.177 millimeter), 0.008 inch (0.203 millimeter), 0.009 inch (0.228 millimeter), and 0.010 inch (0.254 millimeter). In one suitable embodiment, the bristles 1002 are nylon bristles. However, in other embodiments, bristles 1002 may be any other natural or synthetic material that allows brush 1000 to function as described herein.

With further reference to fig. 10 and 11, in one suitable embodiment, to effect movement of the brush 1000 in the cross-web direction XWD, the brush 1000 is connected to the crank arm 1006 by a rotatable coupling 1008 (e.g., bearing, bushing, etc.). The crank arm 1006 is rotatably connected to the drive wheel 1010 by a second rotatable coupling 1012. The second rotatable coupling 1012 is coupled to the off-center position of the drive wheel 1010 such that the crank arm 1006 reciprocates the brush 1000 in the cross-web direction XWD. The drive wheel 1010 is coupled to a motor 1014 to effect rotation of the drive wheel 1010. The position sensor 1016 senses the position of the brush position indicia 1018 coupled to the drive wheel 1010. Thus, the position sensor 1016 may measure the phase (e.g., angular position) and number of revolutions per unit time of the drive wheel 1010. In one embodiment, the drive wheel 1010 is controlled in the range of 0 to 300 revolutions per minute ("revolutions per minute (rpm)") (e.g., 0 to 300 strokes per minute of the brush 1000), such as 0rpm, 25rpm, 50rpm, 75rpm, 100rpm, 125rpm, 150rpm, 175rpm, 200rpm, 225rpm, 250rpm, 275rpm, and 300rpm. In other embodiments, the rpm of the drive wheel 1010 may be greater than 300rpm. Note that since the crank arm 1006 is connected to the drive wheel 1010, a constant rpm of the drive wheel 1010 will result in a sinusoidal speed variation of the brush 1000.

In one suitable embodiment, a second brush (not shown) is positioned in contact with the opposite surface of the web of base material 104. In this embodiment, a second brush, which may be substantially identical to the first brush 1000, is configured to travel in an opposite direction from the first brush, and suitably 180 degrees out of phase with the first brush. The phase of the first brush and the second brush may be determined by the position sensor 1016 and an equivalent position sensor of the second brush. In this embodiment, the contact pressure of the bristles 1002 of the first brush 1000 and the second brush must be low enough so that the individual electrode patterns 800 do not fracture, crack or otherwise cause defects in the individual electrode patterns 800 and to keep the individual electrode patterns 800 attached to the web of base material 104.

In one embodiment, the brush width 1022 of the brush 1000 in the cross-web direction XWD is wider than the width of the base material 104 in the cross-web direction XWD. For example, in one embodiment, the brush width 1022 is of sufficient width such that the bristles 1002 remain in contact with the entire width of the web surface of the base material 104 throughout the entire range of motion of the brush 1000 as the brush 1000 oscillates in the cross-web direction XWD. The rate of oscillation of the brush 1000 and the pressure exerted by the bristles 1002 against the web surface of the base material 104 can be controlled by a user using the user interface 116.

The brushing station 124 may be equipped with a vacuum system configured to generate a vacuum through the brushing station aperture 1020 to evacuate debris that has been brushed off one or more surfaces of the web of base material 104. In this embodiment, the debris may brush off and fall from the web of base material 104 or be sucked through the brushing station aperture 1020. The brushing station aperture 1020 is shown as circular, but may be any shape that allows the brushing station 124 to function as described herein. Further, the upper edges of the brushing station apertures 1020 may be beveled and/or staggered in position to allow the web of base material 104 to more easily pass over them without the edges of the web of base material 104 snagging thereon. In one embodiment, the vacuum may be controlled from 0 to 140 inches of water, such as 0 inches of water, 10 inches of water, 20 inches of water, 30 inches of water, 40 inches of water, 50 inches of water, 60 inches of water, 70 inches of water, 80 inches of water, 90 inches of water, 100 inches of water, 110 inches of water, 120 inches of water, 130 inches of water, and 140 inches of water. In some embodiments, the flow rate of the vacuum is controlled to be from about 0 to 425 cubic feet per minute ("cfm"), such as 0, 25, 50, 75, 100, 125, 150, 175, 200, 225, 250, 275, 300, 325, 350, 375, 400, and 425cfm. In other embodiments, the vacuum and flow rate may be greater than 140 inches of water and 425cfm, respectively. The vacuum and flow rate are controlled within a range such that debris is carried away from the web of base material 104 without creating unnecessary friction between the web of base material 104 and the conveyor system components. In some embodiments, such vacuum and flow rates are applicable to all other components of the system in which the vacuum is used.

In another suitable embodiment, one or both of the first and second brushes may include a load sensor that measures or monitors the pressure exerted by the brushes on the web of electrode material 802. As shown in fig. 8, a web of electrode material 802 refers to a web that has been processed as described herein after a large number of individual electrode patterns 800 have been formed therein. In this embodiment, the first brush and the second brush may be controlled by the user interface 116 to maintain a consistent brushing pressure on the web of electrode material 802 based on brush bristle wear or changes in electrode thickness or surface roughness.

In another suitable embodiment, one or both of the first brush and the second brush are configured to move at least partially in the web-longitudinal direction WD at a rate substantially equal to the rate of the web of electrode material 802, thereby maintaining a substantially zero speed differential between the brush 1000 and the web of electrode material 802 in the web-longitudinal direction WD.

In another suitable embodiment, the brushing station 124 may be equipped with a position sensor 1016 to determine the phase of the first brush and the second brush. In one such embodiment, the position sensor 1016 may measure the position of the brush position indicia 1018 of the first brush and the second brush. In this embodiment, position sensor 1016 determines whether the first and second brushes are within a range of predetermined phase differences, such as 180 degrees out of phase, 90 degrees out of phase, or 0 degrees out of phase, or any other suitable phase difference that allows production system 100 to function as described herein. As used herein, "phase" of a brush refers to the angular position of the brush such that the bristles of two separate brushes are aligned when "in phase".

In another embodiment, an ultrasonic transducer (not shown) may be configured to apply ultrasonic vibrations to one or both of the first and second brushes to facilitate removal of debris from the web of electrode material 802.

With further reference to fig. 2, in one suitable embodiment, the web of base material 104 is conveyed through an air knife 126. As used herein, the term "air knife" refers to the use of a device that blows high pressure air onto the web of base material 104. The high pressure air contacts the surface of the web of base material 104 and removes debris therefrom. The air knife 126 is controlled to supply air at a pressure/velocity such that the individual electrode patterns 800 do not fracture, crack or otherwise cause defects in the individual electrode patterns 800 and maintain the individual electrode patterns 800 attached to the web of base material 104. In another embodiment, a second air knife (not shown), similar to air knife 126, is configured to blow air at the opposite surface of the web of base material 104 and remove debris therefrom. In this embodiment, the second air knife may blow air in the same direction as the first air knife 126, or in a direction opposite the first air knife 126, or in any other direction that allows the air knife 126 to function as described herein. In one embodiment, the air knife 126 station is equipped with a vacuum that assists in removing debris that has been removed by the air knife 126.

Referring to fig. 8, after processing by the laser systems 120a-c and cleaning by the brushing station 124 and the air knife 126, the web of base material 104 exits the cleaning station in the form of a web containing a plurality of individual electrode patterns 800 (collectively referred to as a web of electrode material 802) located within the web of base material 104.

With further reference to fig. 2, 8, and 12, in one embodiment, a web of electrode material 802 passes through inspection station 128. Inspection station 128 is a device configured to analyze the web of electrode material 802 and identify defects thereon. For example, in one embodiment, inspection station 128 is a visual inspection device that includes a camera 1200, and camera 1200 may be a digital camera, such as a digital 3-D camera, configured to analyze individual electrode patterns 800 on a web of electrode material 802. In one embodiment, camera 1200 is a digital light camera including CMOS with a sensitivity of 4800 ten thousand pixels. The camera 1200 is optically coupled to a lens 1202, which lens 1202 may be a wide field lens. In one embodiment, lens 1202 is a telecentric lens. The lens 1202 is held in place by a lens mount 1204, in one embodiment, the lens mount 1204 is adjustable in a vertical direction V to control the focus of the lens 1202. The lens 1202 is intended to focus on the web of electrode material 802 as the web passes the inspection plate 1206. In one embodiment, the inspection plate 1206 includes a transparent or translucent top 1208, the top 1208 allowing light from a light source (not shown) housed within the inspection plate 1206 to illuminate therethrough to create a backlight. In one suitable embodiment, the intensity and/or color of the light may be controlled through the user interface 116. In one embodiment, one or more additional light sources (e.g., upstream light and downstream light) illuminate the web of electrode material 802 while the web of electrode material 802 is located within inspection station 128. In some embodiments, the intensity and color of each light source is independently controllable. In one embodiment, the backlight includes diffuse low-angle annular light. The web of electrode material 802 may be secured by a gear 1210 and conveyed through the inspection plate 1206, the gear 1210 being configured to engage the draw hole 612 of the web of electrode material 802. In so doing, the web of electrode material 802 is held taut against the inspection plate 1206 to substantially decurl the web of electrode material 802. Each of the inspection plate leading edge 1214 and the inspection plate trailing edge 1216 may be beveled (e.g., at an angle similar to angle a) to allow a web of electrode material 802 to pass smoothly thereover without obstruction.

With continued reference to fig. 12, in one embodiment, the inspection station 128 includes a trigger sensor 1212 that detects a predetermined feature of the web of electrode material 802, such as the fiducial feature 602, the longitudinal edge kerf 600, or any other feature that allows the inspection station 128 to function as described herein. Upon detection of the predetermined feature, the trigger sensor 1212 sends a signal directly to the camera 1200, or indirectly through the user interface 116, to trigger the camera 1200 to image an electrode of the web of electrode material 802. Camera 1200 may be configured to detect one or more metrics such as the height of the electrodes, the size or shape of features cut by one of laser systems 120a-120c (fig. 2), the spacing (distance) between the electrodes, or any other feature that allows inspection station 128 to function as described herein after imaging the electrodes. For example, in one suitable embodiment, inspection station 128 detects whether ablation portion 404 (fig. 4), longitudinal edge cuts 600, fiducial features 602, draw holes 612, spacing between individual electrode patterns 800, offset of draw holes 612 in the cross-web and web directions, and first perforations 608 and second perforations 610 (fig. 6) are within predetermined tolerances of size, shape, position, and orientation. In one suitable embodiment, the user may use the user interface 116 to control which features are checked.

In one embodiment, during analysis at inspection station 128, the web of electrode material 802 remains substantially flat, such as by applying a balancing vacuum or fluid (e.g., air) flow on opposite sides of the web of electrode material 802. In this embodiment, by making the web of electrode material 802 flat during inspection, more accurate imaging and analysis can be performed on the web of electrode material 802, thus enabling higher quality error and defect detection.

In one embodiment, inspection station 128 may be configured to provide in-line metering of the web of base material 104 and/or the web of electrode material 802. For example, inspection station 128 may be configured to measure metrics such as web thickness, size and shape of individual electrode patterns 800, and the like as the web is conveyed in web machine direction WD. These metrics may be transmitted to the user interface 116 for viewing or memory storage, or otherwise used to adjust production parameters of the production system 100.

In one embodiment, in the event that inspection station 128 determines that a defect exists on the web of electrode material 802 (FIG. 8), defect marking system 130 (FIG. 2) will mark the web of electrode material 802 to identify such a defect. Defect marking system 130 may be a laser etching device, a printer, a stamper, or any other marking device capable of providing a mark on the web of electrode material 802 that indicates the presence of a defect. In another suitable embodiment, defect marking system 130 is controllable to mark the web of electrode material 802 with one or both of an identification number (ID) and a Known Good Electrode (KGE), thereby allowing the web of electrode material 802 to be further marked with a grade such as grade a, grade B, grade C, etc., in order to indicate a quality measurement (e.g., a number or type of defect) of a particular electrode within the web of electrode material 802.

After processing (also referred to as machining) the web of base material 104 into a web of electrode material 802, the web of electrode material 802 has a 25% to 90% decrease in web strength in the web machine direction WD as compared to an unprocessed (also referred to as un-machined) web of base material 104. Referring to fig. 8A, a portion of a web of electrode material 802 is shown. In this embodiment, the web of electrode material 802 includes electrode clusters EC that include five individual electrode patterns 800 separated by tie bars 614. However, it should be understood that in other embodiments, the electrode clusters EC may include any number of individual electrode patterns 800, including one or more, such as 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or any other number of individual electrode patterns 800 between two tie bars 614. Width W of electrode cluster _EC Is defined as the distance in the web machine direction WD between the center point of the first individual electrode pattern 800 of one electrode cluster EC and the center point of the first individual electrode pattern 800 in the second electrode cluster EC.

In an exemplary embodiment, the cross-web span S of the web in the cross-web direction _W Is 3 mm, and each individual electrode pattern 800 has a width in the web longitudinal direction WDW _EP Is X mm. In this embodiment, the web of electrode material 802 has a web strength reduction value in the web longitudinal direction WD of 33% compared to the web of raw base material 104. The web strength reduction value is calculated as width W _EP Divided by cross-web span S _W (i.e., X mm/3X mm = 0.33).

In another exemplary embodiment, the cross-web span S of the web in the cross-web direction _W Is 1.5 mm, and the width W of each individual electrode pattern 800 in the web longitudinal direction WD _EP Is 1.3 mm. In this embodiment, the web of electrode material 802 has a web strength reduction value in the web longitudinal direction WD of 87% compared to the web of raw base material 104. The web strength reduction value is calculated as W _EP Sw (i.e. 1.3X/1.5 x=0.87). An electromechanical or hydraulic material tester, such as an Instron brand tester, having at least force feedback and which may include displacement feedback, is used to verify and measure web strength of the web of electrode material 802 in the web machine direction WD as the breaking strength of the web of electrode material 802.

In another exemplary embodiment, the web of electrode material 802 has a reduced strength in the cross-web direction XWD compared to the web of base material 104. In the first exemplary embodiment, the electrode cluster width W in the web longitudinal direction WD _EC Is 6 mm, the width W of the tie bars 614 in the web longitudinal direction WD _TB Is X mm, width W of individual electrode pattern 800 in web longitudinal direction WD _EP Is X mm, and the length L of the individual electrode pattern 800 in the cross-web direction XWD _E Is 1.7 mm. In this embodiment, the web of electrode material 802 has a strength reduction value in the cross-web direction XWD of about 77% compared to the web of raw base material 104. In another exemplary embodiment, the electrode cluster width W _EC Width W of tie bar 614 is 10Xmm _TB Width W of individual electrode pattern 800 at 0 mm (i.e., no tie bars 614) _EP Is 2 mm, and the length L of the single electrode pattern 800 _E 1.7Xmm. In this embodiment, the web of electrode material 802 is in the cross-web direction XWD compared to the web of unprocessed base material 104The intensity reduction value was about 92%. An electromechanical or hydraulic material tester, such as an Instron brand tester, having at least force feedback and which may include displacement feedback, is used to verify and measure web strength of the web of electrode material 802 as the breaking strength of the web of electrode material 802.

With further reference to fig. 9, the web of electrode material 802 is then fed to a rewind roll 134 where it is wound with the web of onsert material 138 to form a spool 900 having alternating layers of web of electrode material 802 and web of onsert material 138.

In one suitable embodiment, the user interface 116 may include a memory and a processor configured to store and execute instructions to cause the production system 100 to function as described herein. The user interface 116 may also include a display device (e.g., an LCD or LED display) and a set of controllers or virtual controllers that allow a user to control and adjust parameters of the production system 100, as well as view metrics such as web transport speed, tension, defect count, and any other parameters that allow the production system 100 to function as described herein.

In use, referring to fig. 2, the base unwind roll 102 of the production system 100 is loaded with a web of base material 104. The web of base material 104 passes through edge directors 106 to facilitate web unwinding of base material 104. In this embodiment, the web of base material 104 then passes around idler wheel 108a and into the docking station 110. Idler 108a is used to help maintain proper positioning and tension of the web of base material 104 and to change the direction of the web of base material 104. Idler 108a receives the web of base material 104 in a vertical direction and the web portion of base material 104 wraps around idler 108a such that the web of base material 104 exits idler 108a in an output direction that is substantially 90 degrees from the input direction. However, it should be understood that the input and output directions may vary without departing from the scope of the present disclosure. In some embodiments, the production system 100 may use a plurality of idler wheels 108a-108x to change the direction of the web of base material 104 as it is conveyed through the production system 100 one or more times. In this embodiment, the user unwinds the web of base material 104 through idler wheels 108a-108x, for example as shown in FIG. 2.

In one embodiment, the splicing station 110 is used to splice two separate webs together. In this embodiment, the first web of base material 104 is unwound such that a trailing edge (not shown) of the first web of base material 104 stops within the splice station 110, and a leading edge (not shown) of the second web of base material 104 is unwound into the splice station 110 such that the trailing edge of the first web and the leading edge of the second web are adjacent to each other. The user then applies an adhesive, such as tape, glue, or other suitable adhesive, to join the leading edge of the second web to the trailing edge of the first web, thereby forming a seam between the two webs and creating a continuous web of base material 104. Such a process may be repeated for a number of webs of base material 104, as directed by the user.

In one suitable embodiment, after leaving the splicing station 110, the web of base material 104 is transported in the web longitudinal direction WD to the nip roller 112. Nip roll 112 is controlled via user interface 116 to adjust/maintain the speed at which the web of base material 104 is conveyed through production system 100. The web of base material 104 is pressed against each of two adjacent rollers 114 of the nip roller 112, wherein the pressure is large enough to allow friction of the rollers to move the web of base material 104, but the pressure is also low enough to avoid any significant deformation or damage to the web of base material 104.

In one embodiment, during use, the speed of the web of base material 104 is controlled by controlling the rotational speed of the high friction roller of the nip roller 112 via the user interface 116. In various other embodiments, the production system 100 may include one or more additional rolls 122, 132 that help control the speed of the web of base material 104, and through which the web of base material 104 is conveyed. In this embodiment, the speed of the additional nip rollers 122, 132 may be controlled via the user interface 116. In use, when multiple nip rollers 112, 122, 132 are used, each of the speeds of each nip roller 112, 122, 132 may be set to the same speed through the user interface 116, or to different speeds as desired, such that the web of base material 104 is smoothly conveyed through the production system 100.

In use, in one embodiment, the web of base material 104 is unwound by dancer 118. In this embodiment, a pair of dancer rollers 118 rotate about their central axes to passively adjust the tension on the web of base material 104.

With further reference to fig. 2, in use, a web of base material 104 is conveyed through one or more laser systems 120a, 120b, 120c. The embodiment shown in FIG. 2 includes three laser systems 120a-c, but it should be understood that any number of laser systems 120 may be used to allow production system 100 to function as described herein.

The use of the production system 100 is further described with reference to fig. 2-6. The web of base material 104 is conveyed through laser systems 120a-c in a web longitudinal direction WD. In one embodiment, the web of base material 104 is conveyed into the laser system 120a in a first state 400 that has not been ablated or cut. The web of base material 104 is conveyed over the suction cups 306 and, thus, over the plurality of vacuum holes 406. The vacuum holes 406 are in fluid communication with the vacuum device 308, and the vacuum device 308 is controlled by the user interface 116 to apply vacuum pressure to the web of base material 104 as the web of base material 104 passes over the vacuum holes 406. The vacuum pressure is controlled to maintain the web of base material 104 in a substantially flat/planar state as the web of base material 104 is conveyed across the suction cups 306. In one used embodiment, the vacuum pressure through the vacuum holes 406 is monitored and adjusted in real time via the user interface 116 to ensure that the web of base material 104 remains substantially flat across the suction cups 306 and does not lift or bend during processing.

Referring to fig. 4, the web of base material 104 is conveyed through the opening 410 of the suction cup 306 and further through the chamfer 416 of the downstream edge 414. In this embodiment, the chamfer 416 facilitates the web of base material 104 to pass the downstream edge 414 without catching or retarding the web of base material 104 on the downstream edge 414.

With further reference to fig. 3-5, in one use embodiment, a web of base material 104 is ablated by laser beam 302 (fig. 3) to form ablated section 404 (fig. 4) in the web of base material 104. In one embodiment, the web of base material 104 is anode material 502, and ablative portion 404 removes anode active material layer 508 to expose anode current collector layer 506 (fig. 5). In another embodiment, the web of base material 104 is cathode material 504 and ablative portion 404 removes cathode active material layer 512 to expose cathode current collector layer 510.

In use, when laser system 120a is used to create ablative portions 404 in a web of base material 104, the power of laser beam 302 is controlled by user interface 116 to a level that enables complete or substantially complete removal of the coating, but without damaging or cutting through the current collector layer. In use, the laser beam 302 is controlled, for example by the user interface 116, to create the ablation portion 404 as the web of base material 104 moves and is conveyed in the web machine direction WD. The laser beam 302 is controlled such that ablations 404 are created on each side of the web of base material 104, as best shown in fig. 5. In one used embodiment, after ablation portion 404 is fabricated, laser system 120a is controlled to cut fiducial features 602 in the web of base material 104, as described further herein. In some embodiments, multiple lasers are used, each laser ablating a portion of the web of base material 104 so that each laser produces one or more ablations 404 to increase the throughput of the production system 100.

With further reference to fig. 2, 3, and 4, at another stage of use of the production system 100, the web of base material 104 is conveyed in the web longitudinal direction WD toward the cutting region 408 of the laser system 120 a. In this embodiment, the opening 410 is in fluid communication with the vacuum device 308, and the vacuum device 308 is controlled to create a vacuum pressure on the web of base material 104 as the web of base material 104 passes through the opening 410. In another embodiment, the second vacuum is controlled to balance the pressure on the web of base material 104 opposite the suction cups 306. In this embodiment, the balance of the pressure is monitored and controlled to maintain the web of base material 104 in a substantially flat/planar state as the web of base material 104 passes through opening 410 and at a consistent height to facilitate focusing of laser beam 302 on the web of base material 104.

In one use embodiment, the laser system 120a is controlled to cut one or more patterns in the web of base material 104 as the web of base material 104 is positioned over the opening 410. Referring to fig. 6, the laser system 120 is controlled to cut one or more longitudinal edge cuts 600 to define longitudinal edges of the electrodes in the cross-web direction XWD. While the web of base material 104 is being conveyed in the web longitudinal direction WD, a longitudinal edge cut 600 is cut by cutting the web of base material 104 in the web transverse direction XWD using a laser beam 302. For example, in one embodiment, the path movement of the laser beam 302 is controlled and/or synchronized with the movement of the web of base material 104 in the web longitudinal direction WD. Thus, the travel path of the laser beam 302 is at an angle relative to the web longitudinal direction WD to account for movement of the web of base material 104 in the web longitudinal direction WD. In this embodiment, a compensation factor is applied to the path of the laser beam 302 to allow cutting in the cross-web direction XWD while the web of base material 104 is traveling continuously in the cross-web direction WD. In this embodiment, as the web of base material 104 moves in the web longitudinal direction WD, the laser beam 302 is projected onto the web of base material 104 at an initial cutting location 604 and is then controlled to travel in the cross-web direction XWD and the web longitudinal direction WD until a cutting end location 606 is reached to create a longitudinal edge cut 600. It should be appreciated that the angle at which the control laser beam 302 travels varies based on the speed of the web of base material 104 in the web longitudinal direction WD. In another embodiment, the web of base material 104 is temporarily stopped during the laser machining operation, and thus, the path of the laser beam 302 need not take into account the traveling motion of the web of base material 104. Such an embodiment may be referred to as a step-and-repeat process. During laser processing, one or more of the laser systems 120a-c use repeated alignment features, such as the fiducial feature 602, to adjust and/or align the laser beam 302 during laser processing operations, for example, to compensate for possible variations in positioning of the web of base material 104.

With further reference to fig. 6, in one use embodiment, the laser system 120a is controlled to cut one or more repeated alignment features, such as a plurality of fiducial features 602, in the web of base material 104. The fiducial features 602 are cut at predetermined/known locations on the web of base material 104. In one embodiment used, the fiducial features 602 are tracked by one or more visual inspection devices 310, 312 to measure the position and travel speed of the web of base material 104. The measurement of the fiducial feature 602 is then used to accurately maintain the front-to-back alignment of the pattern on the web of base material 104 in the web longitudinal direction WD and the web transverse direction XWD. In some use embodiments, the laser system 120a cuts a plurality of traction holes 612 and/or fiducial features 602. In various other embodiments, the fiducial features 602 have been preformed in the web of base material 104 such that one or more laser systems 120a-c use them for positioning/alignment as described above.

Referring to fig. 2 and 6, in one suitable use embodiment, the control laser system 120a cuts first perforations 608 and second perforations 610 in the web of base material 104 as part of a single electrode pattern 800 as the web of base material 104 moves in the web machine direction WD. The first perforation 608 is formed by laser cutting using the laser beam 302 while the web of base material 104 is over the opening 410 in the suction cup 306. The first perforations 608 are formed as linear slits (e.g., through-cuts) in a direction aligned with the web longitudinal direction WD. Importantly, the first perforation 608 is cut such that it does not span the entire width W of the electrode _E Extending. Instead, the laser system 120a is controlled to cut the pattern such that the outer tear strip 700 remains on the upstream and downstream edges of the first perforations 608 to ensure that the individual electrode patterns 800 remain connected to the web of base material 104.

With further reference to fig. 6 and 7, in use, the second perforations 610 are cut inboard (in the cross-web direction XWD) of the first perforations 608. In this use embodiment, the second perforations 610 are cut into a row of slits in the web longitudinal direction WD, which slits are separated by the inner tear strip 702. In the illustrated embodiment, the second perforation 610 is cut to intersect the through-hole 704. In the illustrated embodiment, inner tear strip 702 is cut to a length at least twice the length of outer tear strip 700, but may be cut to a different length to allow production system 100 to function as described herein.

In use, referring to fig. 3, 4 and 6, debris resulting from laser cutting the longitudinal edge kerf 600, the fiducial features 602, and the first and second perforations 608, 610 over the opening 410 of the suction cup 306 is allowed to fall through the opening 410 and the vacuum device 308 is controlled to collect debris formed during the laser cutting process.

In one suitable use embodiment, the laser system 120a is configured as a first ablation station. In this embodiment, as described above, laser system 120a is controlled to form ablated section 404 on the first surface of the web of base material 104. After exiting laser system 120a, the web of base material 104 is conveyed onto idler 108d to invert the web of base material 104 such that a second surface (opposite the first surface) of the web of base material 104 is positioned for processing by laser system 120 b. In this embodiment, laser system 120b is configured as a second ablation station and uses fiducial features 602 to ensure alignment of ablation portion 404 in web longitudinal direction WD and web transverse direction XWD. Thus, the laser system 120b is controlled to perform a second ablation process on the opposite surface of the web of base material 104 such that the ablated portions 404 on each surface of the web of base material 104 are aligned in the web longitudinal direction WD and the web transverse direction XWD.

In one use embodiment, the laser system 120c shown in FIG. 2 is configured as a laser cutting station. In this embodiment, the laser system 120c is controlled to perform laser cutting of the longitudinal edge cuts 600 and the first and second perforations 608, 610.

With further reference to fig. 2, 10 and 11, in one use embodiment, the web of base material 104 is conveyed past one or more cleaning stations, such as brushing station 124 and air knife 126, after exiting one or more laser systems 120 a-c. In one suitable use embodiment, the web of base material 104 is conveyed through the brushing station 124 and the bristles 1002 are controlled to gently contact the surface of the web of base material 104 and remove or remove any debris therefrom. The contact pressure of the bristles 1002 on the surface of the web of base material 104 is controlled to be low enough so that the individual electrode patterns 800 do not fracture, crack or otherwise cause defects in the individual electrode patterns 800 and remain attached to the web of base material 104.

With further reference to fig. 10 and 11, in one suitable use embodiment, the movement of the brush 1000 in the cross-web direction XWD is controlled by controlling the motor 1014 to effect rotation of the drive wheel 1010. The position sensor 1016 is controlled to sense the position of the brush position indicia 1018 to measure the phase (e.g., angular position) and number of revolutions per unit time of the drive wheel 1010.

In one suitable use embodiment, a second brush (not shown) is controlled to contact an opposite surface of the web of base material 104. In this embodiment, a second brush, which may be substantially identical to the first brush 1000, is controlled to travel in the opposite direction to the first brush 1000, and suitably 180 degrees out of phase with the first brush 1000. The phase of the first brush 1000 and the second brush may be monitored by the position sensor 1016 and an equivalent position sensor of the second brush. In this embodiment, the contact pressure of the bristles 1002 of the first brush 1000 and the second brush together are controlled low enough that the individual electrode patterns 800 do not fracture, crack or otherwise cause defects in the individual electrode patterns 800 and remain attached to the web of base material 104.

In use, a user can control the rate of oscillation of the brush 1000 and the pressure exerted by the bristles 1002 against the surface of the web of base material 104 via the user interface 116.

In one used embodiment, the brushing station 124 is equipped with a vacuum system and controls the generation of a vacuum through the brushing station orifice 1020 to expel debris brushed off one or more surfaces of the web of base material 104. In this embodiment, debris is brushed off the web of base material 104 and falls off, or the aspirators pass through brushing station apertures 1020.

In another suitable use embodiment, one or both of the first brush 1000 and the second brush include a load sensor that can measure or monitor the sensor to determine the pressure that the brush 1000 is applying to the web of electrode material 802. In this embodiment, the first brush 1000 and the second brush are controlled by the user interface 116 to maintain a substantially uniform brushing pressure on the web of electrode material 802 based on brush bristle wear or changes in electrode thickness or surface roughness.

In another suitable use embodiment, one or both of the first brush 1000 and the second brush are controlled to move at least partially in the web-longitudinal direction WD at a rate substantially equal to the rate of the web of electrode material 802 so as to maintain a substantially zero speed differential between the brush 1000 and the web of electrode material 802 in the web-longitudinal direction WD.

In another suitable use embodiment, the brushing station 124 is equipped with a position sensor 1016 for determining the phase of the first brush 1000 and the second brush. In this embodiment, position sensor 1016 measures the position of brush position indicia 1018 of first brush 1000 and second brush. In this embodiment, position sensor 1016 determines whether the first brush and the second brush are within a range of predetermined phase differences, such as 180 degrees out of phase, 90 degrees out of phase, or 0 degrees out of phase, or any other suitable phase difference that allows production system 100 to function as described herein, and allows correction thereof or provides an alert to the user that the brush is not properly phased through user interface 116 or other alert device.

In another used embodiment, an ultrasonic transducer (not shown) is activated to apply ultrasonic vibrations to one or both of the first and second brushes to facilitate removal of debris from the web of electrode material 802.

With further reference to fig. 2, in one suitable use embodiment, a web of base material 104 is conveyed through an air knife 126. In this embodiment, high pressure air is controlled to contact the surface of the web of base material 104 to remove debris therefrom. The air knife 126 is controlled to supply air at a pressure/velocity, for example, through the user interface 116, such that the individual electrode patterns 800 do not fracture, crack, or otherwise cause defects in the individual electrode patterns 800, and keep the individual electrode patterns 800 attached to the web of base material 104. In another embodiment, a second air knife is controlled to blow air against the opposite surface of the web of base material 104 to remove debris therefrom. In this embodiment, the second air knife is controlled to blow air in the same direction as the first air knife 126, or in a direction opposite the first air knife, or in any other direction that allows the air knife 126 to function as described herein. In another embodiment, the air knife 126 is equipped with a vacuum device that is controlled to facilitate removal of debris that has been removed by the air knife 126.

Referring to fig. 8, after processing by the laser systems 120a-c and cleaning by the brushing station 124 and the air knife 126, the web of base material 104 exits the cleaning station in the form of a web containing a plurality of individual electrode patterns 800 (collectively referred to as a web of electrode material 802) located within the web of base material 104.

With further reference to fig. 2, 8, and 12, in one used embodiment, a web of electrode material 802 is conveyed through inspection station 128. Inspection station 128 is controlled to analyze the web of electrode material 802 and identify defects thereon. For example, in one embodiment, inspection station 128 is a visual inspection device that includes a camera 1200. The lens 1202 is intended to focus on the web of electrode material 802 as the web passes the inspection plate 1206. In one embodiment of use, the inspection plate 1206 includes a transparent or translucent top 1208 that allows light from a light source (not shown) housed within the inspection plate 1206 to pass therethrough. In one suitable embodiment, the intensity and/or color of the light is controlled by the user interface 116. In one embodiment used, the web of electrode material 802 is conveyed through the inspection plate 1206 by a gear 1210 that engages a tractor hole 612 of the web of electrode material 802. In so doing, the web of electrode material 802 is held taut against the inspection plate 1206 to substantially decurl the web of electrode material 802.

Referring additionally to fig. 12, in one used embodiment, inspection station 128 includes a trigger sensor 1212 that is controlled to detect a predetermined characteristic of the web of electrode material 802, such as a fiducial feature 602, a longitudinal edge cut 600, or any other feature that allows inspection station 128 to function as described herein. Upon detection of the predetermined feature, the trigger sensor 1212 sends a signal directly to the camera 1200, or indirectly through the user interface 116, to trigger the camera 1200 to image an electrode of the web of electrode material 802. After imaging the electrodes, the camera 1200 is controlled to detect one or more metrics, such as the height of the electrodes, the size or shape of features cut by one of the laser systems 120a-120c (fig. 2), the spacing (distance) between the electrodes, or any other feature that allows the inspection station 128 to function as described herein. For example, in one suitable embodiment, inspection station 128 is controlled to detect whether ablated section 404 (fig. 4), longitudinal edge cut 600, fiducial feature 602, and first and second perforations 608 and 610 (fig. 6), single electrode structure web cross direction XWD dimension, single electrode structure web longitudinal direction WD dimension, single electrode active area offset, and any other ablated section or cut of the web of electrode material 802 are within a predetermined tolerance of size, shape, position, cross-machine direction spacing, and orientation, and communicate this message to the user via user interface 116. In one suitable embodiment, the user may use the user interface 116 to control which features are checked. In yet another embodiment, inspection station 128 may detect cluster identifiers of one or more electrode structures of the web of electrode material 802.

In one used embodiment, inspection station 128 is used to meter the web of base material 104 and/or the web of electrode material 802 on-line. In this embodiment, inspection station 128 is controlled to measure metrics such as web thickness, size and shape of individual electrode patterns 800, etc. as the web is conveyed in web machine direction WD. These metrics are communicated to the user interface 116 for viewing or memory storage or otherwise used to adjust production parameters of the production system 100.

In one used embodiment, if inspection station 128 determines that a defect is present on the web of electrode material 802 (fig. 8), defect marking system 130 (fig. 2) is controlled to mark the web of electrode material 802 using a laser etching device, printer, die, or any other marking device capable of providing a mark on the web of electrode material 802 indicating the presence of a defect to identify such a defect. In another suitable use embodiment, defect marking system 130 is controlled to mark the web of electrode material 802 with one or both of an identification number (ID) and a Known Good Electrode (KGE), allowing the web of electrode material 802 to be further marked with a grade such as grade a, grade B, grade C, etc., to indicate a quality measurement (e.g., number or type of defect) of a particular individual electrode pattern 800 within the web of electrode material 802.

With further reference to fig. 9, the web of electrode material 802 is then transferred to a rewind roll 134 where it is wound with the web of onsert material 138 to form a spool 900 having alternating layers of web of electrode material 802 and web of onsert material 138.

In one suitable use embodiment, the web of electrode material 802 is rewound by the rewind roll 134 along with the web of onsert material 138 unwound by the onsert roll 136 to form a roll of electrodes 140 in which the layers of the web of electrode material 802 are separated by the web of onsert material 138. In some embodiments, the web of electrode material 802 is rewound via the rewind roll 134 without the web of onsert material 138.

In one used embodiment, the web of base material 104 has a layer of tape (not shown) that is adhered to one or both surfaces of the anode active material layer 508 or the cathode active material layer 512, respectively. In this embodiment, in use, the adhesive layer is removed after ablation and cutting (as described above) to remove unwanted material or debris.

In one embodiment used, one or more rollers of the conveyor system are not perfectly circular, and therefore the rollers have an eccentricity. In such embodiments, the eccentric rollers are mapped to determine the radius-to-radial position. The laser systems 120a-c are then controlled to adjust the position of the laser beam 302 based on the roller mapping to account for the eccentricity.

Referring to fig. 14-16, a web of electrode material 802 is used to produce a battery. In this embodiment, individual rolls of electrode material 1402, 1404, and 1406A and 1406B are unwound and stacked in an alternating configuration comprising at least one layer of cathode 1402 and anode 1404 separated by a separator material 1406. It should be appreciated that rolls of electrode material 1402, 1404, and 1406A and 1406B have been produced as webs of electrode material 802 as described herein. In one suitable embodiment, rolls of electrode material 1402, 1404, 1406A, and 1406B are combined into a multilayer stack 1500. In this embodiment, the multilayer stack 1500 includes a centrally located anode current collector layer 506, an anode active material layer 508, an electrically insulating separator material 500, a cathode active material layer 512, and a cathode current conductor layer 510, which are in the form of a stack. Additional stacks may be combined by alternating layers of the anode 1404, separator 1406, and reels of cathode 1402 to form the desired number of layers of the multi-layer stack 1500. Alignment pins 1600 are used to align the layers of the multi-layer stack 1500, the alignment pins 1600 being driven through the fiducial features 602 (fig. 16B).

In another embodiment, for example for a solid state secondary battery, the components of the solid state battery may be stacked (after processing as described herein) in a manner that sequentially includes a positive electrode current collector, an electrode layer comprising a positive active electrode material, an ionic conductor, a binder, and an electronic conductor, a solid state electrolyte, and a negative electrode current collector, such as described in U.S. patent No. 9,553,332 referenced above.

In one embodiment, multilayer stack 1500 is then placed in a compression constraint device 1602 having pressure plates 1604, 1606, where pressure plates 1604, 1606 apply pressure to multilayer stack 1500 in the direction indicated by pressure arrow P. The pressure applied to the multilayer stack 1500 may be adjusted using the user interface 116 to control the pressure P applied to the multilayer stack 1500 by the pressure plates 1604, 1606. After sufficient pressure P is applied to the multilayer stack 1500, the alignment pin 1600 may move in the removal direction R, which causes the second perforation 610 to fracture along its length, such that the ablated 404 (electrode tab) becomes the outer edge of the multilayer stack 1500, as shown in fig. 16C.

After the second perforation 610 is ruptured, the multi-layer stack 1500 is advanced to a tab welding station to weld the bus bars 1700 and 1702 to the ablation site 404 to form the stacked cell 1704. Prior to welding, the bus bars 1700, 1702 are placed through the bus bar openings 1608 of the respective electrodes. In one embodiment, after the bus bars 1700, 1702 have been placed through the bus bar opening 1608, the ablated 404 is folded down toward the bus bars 1700, 1702, respectively, prior to welding. In this embodiment, bus bar 1700 is a copper bus bar and is welded to ablated portion 404 (anode tab) of anode current collector layer 506, and bus bar 1702 is an aluminum bus bar and is welded to ablated portion 404 (cathode tab) of cathode current collector layer 510. However, in various other embodiments, the bus bars 1700 and 1702 may be any suitable conductive material to allow the battery 1804 to function as described herein. The weld may be formed using a laser welder, friction welding, ultrasonic welding, or any suitable welding method for welding the bus bars 1700, 1702 to the ablation portion 404. In one embodiment, each busbar 1700 and 1702 is in electrical contact with all of the ablated 404 of the anode and cathode, respectively.

After the laminated cells 1704 are formed, the laminated cells 1704 enter the packaging station 1800. At the packaging station 1800, the laminated battery cells 1704 are coated with an insulating packaging material, such as a multi-layer aluminum polymer material, plastic, or the like, to form a battery pack 1802. In one embodiment, the battery pack 1802 is evacuated using a vacuum and filled with electrolyte material through an opening (not shown). The insulating packaging material may be sealed around the laminated battery cells 1704 using heat sealing, laser welding, adhesives, or any suitable sealing method. The bus bars 1700 and 1702 remain exposed and uncovered by the battery pack 1802 to allow a user to connect the bus bars 1700 and 1702 to a device or battery charger to be powered. Once the battery pack 1802 is placed on the stacked cells 1704, the complete battery 1804 is defined. In this embodiment, the completed battery 1804 is a 3-D lithium ion type battery. In other embodiments, the completed battery 1804 may be any battery type suitable for production using the apparatus and methods described herein.

In one embodiment, each member of the anode group has a bottom, a top, and a longitudinal axis A _E (FIG. 7). In one embodiment, the longitudinal axis A _E Extending in the cross-web direction XWD from its bottom to its top. In an alternative embodiment, the longitudinal axis A _E Extending from its bottom to its top in the web longitudinal direction WD. In one embodiment, the members of the anode group are formed from a web of base material 104 that is the anode material 502. In addition, each member of the anode group has a longitudinal axis (A _E ) Length of measurement (L _E ) (FIG. 6A), in a direction perpendicular to the longitudinal axis (A _E ) Width (W) measured in the direction (e.g., web longitudinal direction WD) _E ) And in a direction perpendicular to the length (L _E ) And width (W) _E ) A height (H) measured in the direction of the measurement direction of each of _E ) (FIG. 6A).

Length of anode group member (L _E ) Will vary depending on the energy storage device and its intended use. In general, however, the length (L _E ) Typically in the range of about 5mm to about 500 mm. For example, in one such embodiment, the length (L _E ) From about 10mm to about 250mm. As a further example, in one such embodiment, the length (L _E ) From about 25mm to about 100mm.

Width of anode group member (W _E ) Will also vary depending on the energy storage device and its intended use. In general, however, each member of the anode group typically has a width (W) in the range of about 0.01mm to 2.5mm _E ). For example, in one embodiment, the width (W _E ) Will be in the range of about 0.025mm to about 2 mm. As a further example, in one embodiment, the width (W _E ) Will be in the range of about 0.05mm to about 1 mm.

Height of anode group member (H _E ) Will also vary depending on the energy storage device and its intended use. In general, however, the heights of the anode group members (H _E ) Typically about 0.0In the range of 5mm to about 10 mm. For example, in one embodiment, the height (H _E ) In the range of about 0.05mm to about 5 mm. As a further example, in one embodiment, the height (H _E ) Will be in the range of about 0.1mm to about 1 mm. According to one embodiment, the members of the anode group comprise one or more first electrode members having a first height and one or more second electrode members having a second height different from the first height. In yet another embodiment, different heights may be selected for the one or more first electrode members and the one or more second electrode members to accommodate a predetermined shape of an electrode assembly (e.g., multi-layer stack 1500 (fig. 15)), such as an electrode assembly shape having different heights along one or both of the longitudinal axis and/or the transverse axis, and/or to provide a predetermined performance characteristic for a secondary battery.

Typically, the length of the anode group member (L _E ) Far greater than its width (W _E ) And height (H) _E ) Each of which is a single-phase alternating current power supply. For example, in one embodiment, L for each member of the anode group _E And W is equal to _E And H _E The ratio of each of (a) is at least 5:1 (i.e., L _E And W is equal to _E Is at least 5:1, and L _E And H is _E At least 5:1, respectively). As a further example, in one embodiment, L _E And W is equal to _E And H _E Is at least 10:1. As a further example, in one embodiment, L _E And W is equal to _E And H _E Is at least 15:1. As a further example, in one embodiment, for each member of the anode group, L _E And W is equal to _E And H _E Is at least 20:1.

In one embodiment, the heights of the anode group members (H _E ) And width (W) _E ) The ratio of (2) is at least 0.4:1, respectively. For example, in one embodiment, for each member of the anode group, H _E And W is equal to _E Will be at least 2:1, respectively. As a further example, in oneIn examples, H _E And W is equal to _E Will be at least 10:1, respectively. As a further example, in one embodiment, H _E And W is equal to _E Will be at least 20:1, respectively. Typically, however, H _E And W is equal to _E Typically less than 1000:1, respectively. For example, in one embodiment, H _E And W is equal to _E Will be less than 500:1, respectively. As a further example, in one embodiment, H _E And W is equal to _E Will be less than 100:1, respectively. As a further example, in one embodiment, H _E And W is equal to _E Will be less than 10:1, respectively. As a further example, in one embodiment, for each member of the anode group, H _E And W is equal to _E Will be in the range of about 2:1 to about 100:1, respectively.

In one embodiment, the members of the cathode group are formed from a web of base material 104 that is the cathode material 504. Referring now to fig. 6B, each member of the cathode group has a bottom, a top, and a longitudinal axis (a _CE ) The longitudinal axis extends from the bottom to the top thereof in the cross-web direction XWD and in a direction generally perpendicular to the alternating sequential progression of the negative and positive electrode structures. In addition, each member of the cathode group has a longitudinal axis (A _CE ) Length of measurement (L _CE ) Width (W _CE ) And along a direction perpendicular to the length (L _CE ) And width (W) _CE ) Height (H) measured in the measurement direction of each of _CE )。

Length of cathode group member (L _CE ) Will vary depending on the energy storage device and its intended use. In general, however, each member of the cathode group typically has a length (L) of about 5mm to about 500mm _CE ). For example, in one such embodiment, each member of the cathode group has a length (L) of about 10mm to about 250mm _CE ). As a further example, in one such embodiment, each member of the cathode group has a length (L _CE )。

Width of cathode group member (W _CE ) Will also vary depending on the energy storage device and its intended use. In general, however, the members of the cathode group will typically have a width (W) in the range of about 0.01mm to 2.5mm _CE ). For example, in one embodiment, the width (W _CE ) Will be in the range of about 0.025mm to about 2 mm. As a further example, in one embodiment, the width (W _CE ) Will be in the range of about 0.05mm to about 1 mm.

Height of cathode group member (H _CE ) Will also vary depending on the energy storage device and its intended use. In general, however, the members of the cathode group typically have a height (H) in the range of about 0.05mm to about 10mm _CE ). For example, in one embodiment, the height (H _CE ) Will be in the range of about 0.05mm to about 5 mm. As a further example, in one embodiment, the height (H _CE ) Will be in the range of about 0.1mm to about 1 mm. According to one embodiment, the members of the cathode group include one or more first cathode members having a first height and one or more second cathode members having a second height different from the first height. In yet another embodiment, different heights may be selected for the one or more first cathode members and the one or more second cathode members to accommodate a predetermined shape of the electrode assembly, such as an electrode assembly shape having different heights along one or both of the longitudinal axis and/or the transverse axis, and/or to provide a predetermined performance characteristic for the secondary battery.

Typically, the length (L _CE ) Far greater than its width (W _CE ) And is much greater than its height (H _CE ). For example, in one embodiment, L for each member of the cathode group _CE And W is equal to _CE And H _CE The ratio of each of (a) is at least 5:1 (i.e., L _CE And W is equal to _CE The ratio of (C) is at least 5:1, L, respectively _CE And H is _CE At least 5:1, respectively). As a further example, in one embodiment, a pair ofAt each member of the cathode group, L _CE And W is equal to _CE And H _CE Is at least 10:1. As a further example, in one embodiment, for each member of the cathode group, L _CE And W is equal to _CE And H _CE Is at least 15:1. As a further example, in one embodiment, for each member of the cathode group, L _CE And W is equal to _CE And H _CE Is at least 20:1.

In one embodiment, the height of the cathode group member (H _CE ) And width (W) _CE ) The ratio of (2) is at least 0.4:1, respectively. For example, in one embodiment, for each member of the cathode group, H _CE And W is equal to _CE Will be at least 2:1, respectively. As a further example, in one embodiment, for each member of the cathode group, H _CE And W is equal to _CE Will be at least 10:1, respectively. As a further example, in one embodiment, for each member of the cathode group, H _CE And W is equal to _CE Will be at least 20:1, respectively. However, for each member of the anode group, H _CE And W is equal to _CE Typically less than 1000:1, respectively. For example, in one embodiment, for each member of the cathode group, H _CE And W is equal to _CE Will be less than 500:1, respectively. As a further example, in one embodiment, H _CE And W is equal to _CE Will be less than 100:1, respectively. As a further example, in one embodiment, H _CE And W is equal to _CE Will be less than 10:1, respectively. As a further example, in one embodiment, for each member of the cathode group, H _CE And W is equal to _CE Will be in the range of about 2:1 to about 100:1, respectively.

In one embodiment, the conductivity of the anode current collector layer 506 is also substantially greater than the conductivity of the anode active material layer 508. For example, in one embodiment, the ratio of the conductivity of the anode current collector layer 506 to the conductivity of the anode active material layer 508 is at least 100:1 when a current is applied to store energy in the device or a load is applied to discharge the device. As another example, in some embodiments, the ratio of the conductivity of the anode current collector layer 506 to the conductivity of the anode active material layer 508 is at least 500:1 when a current is applied to store energy in the device or a load is applied to discharge the device. As another example, in some embodiments, the ratio of the conductivity of the anode current collector layer 506 to the conductivity of the anode active material layer 508 is at least 1000:1 when a current is applied to store energy in the device or a load is applied to discharge the device. As another example, in some embodiments, the ratio of the conductivity of the anode current collector layer 506 to the conductivity of the anode active material layer 508 is at least 5000:1 when a current is applied to store energy in the device or a load is applied to discharge the device. As another example, in some embodiments, the ratio of the conductivity of the anode current collector layer 506 to the conductivity of the anode active material layer 508 is at least 10,000:1 when a current is applied to store energy in the device or a load is applied to discharge the device.

In general, the cathode current collector layer 510 may comprise a metal, such as aluminum, carbon, chromium, gold, nickel, niP, palladium, platinum, rhodium, ruthenium, alloys of silicon and nickel, titanium, or combinations thereof (see "Current collectors for positive electrodes of lithium-based batteries" by a.h. whitehead and m.schreiber, journal of the electrochemical society, 152 (11) a2105-a2113 (2005)). As a further example, in one embodiment, the cathode current collector layer 510 includes gold or an alloy thereof, such as gold silicide. As a further example, in one embodiment, the cathode current collector layer 510 includes nickel or an alloy thereof, such as nickel silicide.

The following examples are provided to illustrate various aspects of the disclosure, but these examples are not limiting and other aspects and/or embodiments may also be provided.

Embodiment 1. A method for scoring a group of electrode structures in a web, the web comprising a conductive layer having opposite front and back sides and an electrochemically active material layer on the front side, on the back side, or on both the front and back sides, the web having a web longitudinal direction and a web transverse direction, the web longitudinal direction and the web transverse direction being orthogonal to each other, the method comprising: controlling tension of the web in the machine direction while forming a series of weakened tear patterns in the web in the machine direction, in the cross-web direction, or in each of the cross-web direction and the machine-web direction, the weakened tear patterns scoring out members of the electrode structure group without releasing the scored out members from the web, wherein each of the scored out members is at least partially defined by a member of the series of weakened tear patterns adapted to facilitate separation of each of the scored out members from the web by application of a force; and forming a series of alignment features in the web, the alignment features being disposed in a cross-web direction or a machine-web direction relative to the scored members, the alignment features each being adapted to locate the scored members of the electrode structure group in the web.

Embodiment 2. A method for scoring groups of electrode structures in a web, the web comprising a conductive layer having opposite front and back sides and an electrochemically active material layer on the front side, on the back side, or on both the front and back sides, the web having a web longitudinal direction and a web transverse direction, the web longitudinal direction and the web transverse direction being orthogonal to each other, the method comprising: supporting a portion of the web on a support surface, the support surface defining an opening; forming a series of weakened tear patterns in the web that score members of the electrode structure groups in the web longitudinal direction, in the web transverse direction, or in each of the web transverse direction and the web longitudinal direction without releasing the scored members from the web, wherein each scored member is at least partially defined by a member of the series of weakened tear patterns adapted to facilitate separation of each scored member from the web by application of a force; and forming a series of alignment features in the web, the alignment features being disposed in a cross-web direction or a machine-web direction relative to the scored members, the alignment features each being adapted to locate the scored members of the electrode structure group in the web, wherein at least one of forming the weakened tear pattern and forming the series of alignment features is performed on a portion of the web above the opening of the support surface for supporting the web.

Embodiment 3. A method for scoring groups of electrode structures or groups of electrode separator structures in a web comprising a web longitudinal direction, a web transverse direction orthogonal to the web longitudinal direction, and an electrically insulating layer, the method comprising: the portion of the web to be laser machined is controlled to lie within about +/-100 microns of the laser focus of the laser beam; laser machining the portion of the web in at least one of a cross-web direction and a machine-web direction to scribe members of electrode structure groups or electrode separator structure groups in the web without releasing the scribed members from the web; and forming in the web a registration feature adapted to locate in the web a member of the or each scribe of the group of electrode structures.

Embodiment 4. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction and a web cross direction orthogonal to the web longitudinal direction, the method comprising: the web is machined in the cross-web direction and the longitudinal web direction to form discontinuous weakened portions, thereby scoring members of the electrode structure groups in the web without releasing the scored members from the web, the strength of the machined web in the web direction being 10% to 75% of the strength of the unmachined web in the web direction.

Embodiment 5. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction, a web cross-direction orthogonal to the web longitudinal direction, an electrochemically active layer, and a conductive layer, the method comprising: machining the web at least in the cross-web direction to scribe members of the electrode structure group in the web without releasing the scribed members from the web; and forming an alignment feature in the web, the alignment feature adapted to locate each scored member of the group of electrode structures in the web.

Embodiment 6. A method for scoring groups of electrode separation structures in a web, the web comprising a web longitudinal direction, a web transverse direction orthogonal to the web longitudinal direction, and an electrically insulating layer, the method comprising: machining the web at least in the cross-web direction to scribe members of the group of electrode separation structures in the web without releasing the scribed members from the web; and forming an alignment feature in the web, the alignment feature adapted to locate each scored member of the group of electrode structures in the web.

Embodiment 7. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction, a web cross-direction orthogonal to the web longitudinal direction, an electrochemically active layer, and a conductive layer, the method comprising: feeding the web to a cutting station; cutting the web at least in the cross-web direction at a cutting station to scribe members of the electrode structure group in the web without releasing the scribed members from the web; and cutting registration features in the web, the registration features adapted to locate each scored member of the group of electrode structures in the web.

Embodiment 8. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction, a web cross-direction orthogonal to the web longitudinal direction, an electrochemically active layer, and a conductive layer, the method comprising: feeding the web to a laser cutting system; cutting registration features in the web using a laser cutting system; establishing a position of the web using the at least one registration feature; and performing at least one of a cutting action and an ablation action on the web based on the established position.

Embodiment 9. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction, a web cross-direction orthogonal to the web longitudinal direction, an electrochemically active layer, and a conductive layer, the method comprising: machining the web at least in the cross-web direction to scribe members of the electrode structure group in the web by forming discontinuous weakened portions defining an outer boundary of each scribed member without releasing the scribed members from the web; and forming an alignment feature in the web, the alignment feature adapted to locate each scored member of the group of electrode structures in the web.

Embodiment 10. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction and a web cross direction orthogonal to the web longitudinal direction, the method comprising: the web is machined in the cross-web direction and the longitudinal web direction to form discontinuous weakened portions, thereby scoring members of the electrode structure groups in the web without releasing the scored members from the web, the strength of the machined web in the cross-web direction being 5% to 30% of the strength of the unmachined web in the cross-web direction.

Embodiment 11. A web comprising an electrochemically active layer and a conductive layer, the web having scored electrode structure groups, each electrode structure of the scored electrode structure groups being separated from adjacent electrode structures by a discontinuous cut in the web, the web further comprising an alignment feature adapted to locate each scored electrode structure of the electrode structure groups in the web.

Embodiment 12. A web comprising a scored group of separation structures, each separation structure of the scored group of separation structures being spaced apart from an adjacent separation structure by a discontinuous cut in the web, the web further comprising an alignment feature adapted to position each scored separation structure of the group of separation structures in the web.

Embodiment 13. A method for scoring a group of electrode structures in a web, the web comprising a web longitudinal direction, a web cross-direction orthogonal to the web longitudinal direction, and at least one of a solid electrolyte, a negative current collector, a positive current collector, and a positive active material, the method comprising: feeding the web to a laser cutting system; cutting registration features in the web using a laser cutting system; establishing a position of the web using the at least one registration feature; and performing at least one of a cutting action and an ablation action on the web based on the established position.

Embodiment 14. A web comprising a solid electrolyte, the web having a scored group of electrode structures, each electrode structure of the scored group of electrode structures being spaced apart from an adjacent electrode structure by a discontinuous cut in the web, the web further comprising an alignment feature adapted to position each scored electrode structure of the group of electrode structures in the web.

Embodiment 15. The method or web of any of the preceding embodiments, wherein the series of weakened tear patterns are formed using a laser.

Embodiment 16. The method or web of any of the preceding embodiments, wherein the series of alignment features are formed using a laser.

Embodiment 17 the method or web of any preceding embodiment, wherein the series of weakened tear patterns, the series of alignment features, or both the series of weakened tear patterns and the series of alignment features are formed using a laser.

Embodiment 18. The method or web of any of the preceding embodiments, wherein the laser has a laser power in the range of 10 watts to 5,000 watts, the laser being a fiber laser, the laser having a laser pulse width type that can be at least one of the following pulse types: a continuous wave (cw) pulse type, a microsecond (μs) pulse type, a nanosecond (ns) pulse type, a picosecond (ps) pulse type, and a femtosecond (fs) pulse type, or a combination thereof.

Embodiment 19. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer is on only one of the front and back sides of the conductive layer.

Embodiment 20. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer is on both the front side and the back side of the conductive layer.

Embodiment 21. The method or web of any of the preceding embodiments, wherein the scored member in the electrode structure group has a length L _E And height H _E Wherein: (i) L (L) _E Measured in the cross-web direction, H _E Measured in the machine direction of the web, or (ii) L _E Measured in the longitudinal direction of the web, H _E Is in the cross-web directionMeasured.

Embodiment 22. The method or web of any of the preceding embodiments, wherein the delineating members of the electrode structure groups have a length L _E And height H _E Wherein L is _E Measured in the cross-web direction, H _E Measured in the longitudinal direction of the web.

Embodiment 23. The method or web of any of the preceding embodiments, wherein the scored member of the electrode structure group has a length L _E And height H _E Wherein L is _E Measured in the longitudinal direction of the web, H _E Measured in the cross-web direction.

Embodiment 24. The method or web of any of the preceding embodiments, wherein the scored members of the electrode structure group have a width W measured in a direction orthogonal to the front and back sides of the web and orthogonal to the web longitudinal and cross-web directions _E 。

Embodiment 25. The method or web of any of the preceding embodiments, wherein L _E And W is equal to _E And H _E Is at least 5:1 (i.e., L) _E And W is equal to _E Is at least 5:1, and L _E And H is _E At least 5:1, respectively).

Embodiment 26. The method or web of any of the preceding embodiments, wherein L _E And W is equal to _E And H _E Is at least 10:1 (i.e., L) _E And W is equal to _E Is at least 10:1, and L _E And H is _E The ratio of (2) is at least 10:1, respectively).

Embodiment 27. The method or web of any of the preceding embodiments, wherein L _E And W is equal to _E And H _E Is at least 15:1 (i.e., L) _E And W is equal to _E Is at least 15:1, and L _E And H is _E At least 15:1, respectively).

Embodiment 28. The method or web of any of the preceding embodiments, wherein L _E And W is equal to _E And H _E Ratio of each ofA ratio of at least 20:1 (i.e., L _E And W is equal to _E Is at least 20:1, and L _E And H is _E At least 20:1, respectively).

Embodiment 29. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is at least 0.4:1, respectively.

Embodiment 30. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratios of (2) to (1), respectively, are at least 2:1.

Embodiment 31. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is at least 10:1, respectively.

Embodiment 32. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is at least 20:1, respectively.

Embodiment 33. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is less than 1,000:1, respectively.

Embodiment 34. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is less than 500:1, respectively.

Embodiment 35. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is less than 100:1, respectively.

Embodiment 36. The method or web of any of the preceding embodiments, wherein H _E And W is equal to _E The ratio of (2) is less than 10:1, respectively.

Embodiment 37 the method or web of any preceding embodiment, wherein H _E And W is equal to _E The ratios of (2) to (1) are in the range of about 2:1 to about 100:1, respectively.

Embodiment 38. The method or web of any of the preceding embodiments, wherein L _E In the range of about 5mm to about 500 mm.

Embodiment 39. The method or web of any of the preceding embodiments, wherein L _E In the range of about 10mm to about 250 mm.

Example 40 according to any of the precedingThe method or web of the embodiment, wherein L _E In the range of about 25mm to about 100 mm.

Embodiment 41. The method or web of any of the preceding embodiments, wherein W _E In the range of about 0.01mm to 2.5 mm.

Embodiment 42. The method or web of any of the preceding embodiments, wherein W _E In the range of about 0.025mm to about 2 mm.

Embodiment 43. The method or web of any of the preceding embodiments, wherein W _E In the range of about 0.05mm to about 1 mm.

Embodiment 44. The method or web of any of the preceding embodiments, wherein H _E In the range of about 0.05mm to about 10 mm.

Embodiment 45. The method or web of any of the preceding embodiments, wherein H _E In the range of about 0.05mm to about 5 mm.

Embodiment 46. The method or web of any of the preceding embodiments, wherein H _E In the range of about 0.1mm to about 1 mm.

Embodiment 47. The method or web of any of the preceding embodiments, wherein the conductive layer has a thickness of at least 10 ³ Conductivity of S/cm.

Embodiment 48. The method or web of any of the preceding embodiments, wherein the conductive layer has a thickness of at least about 10 ⁴ Conductivity of S/cm.

Embodiment 49 the method or web of any preceding embodiment, wherein the conductive layer has a thickness of at least about 10 ⁵ Conductivity of S/cm.

Embodiment 50. The method or web of any of the preceding embodiments, wherein the conductive layer comprises a material suitable for use as a positive current collector layer.

Embodiment 51. The method or web of any of the preceding embodiments wherein the conductive layer comprises aluminum, carbon, chromium, gold, nickel phosphorous (NiP), palladium, platinum, rhodium, ruthenium, titanium, silicon nickel alloy (NiSi), or a combination thereof.

Embodiment 52. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises a cathode active material.

Embodiment 53. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises a transition metal oxide, a transition metal sulfide, a transition metal nitride, a lithium transition metal oxide, a lithium transition metal sulfide, or a lithium transition metal nitride.

Embodiment 54. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises a transition metal oxide, a transition metal sulfide, or a transition metal nitride, wherein the transition metal has a d-shell or f-shell.

Embodiment 55. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises Sc, Y, lanthanoid, actinoid, ti, zr, hf, V, nb, ta, cr, mo, W, mn, tc, re, fe, ru, os, co, rh, ir, ni, pb, pt, cu, ag, or Au.

Embodiment 56. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises LiCoO ₂ 、LiNi _0.5 Mn _1.5 O ₄ 、Li(Ni _x Co _y Al _z )O ₂ 、LiFePO ₄ 、Li ₂ MnO ₄ 、V ₂ O ₅ Molybdenum oxysulfide, phosphate, silicate, vanadate, sulfur compound, oxygen (air), li (Ni) _x Mn _y Co _z )O ₂ And combinations thereof.

Embodiment 57. The method or web of any of the preceding embodiments, wherein the conductive layer comprises a material suitable for use as a negative current collector layer.

Embodiment 58. The method or web of any of the preceding embodiments, wherein the conductive layer comprises copper, nickel, cobalt, titanium, or tungsten, or alloys thereof.

Embodiment 59. The method or web of any preceding embodiment, wherein the electrochemically active material layer comprises an anode active material.

Embodiment 60. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises graphite, soft or hard carbon, or graphene.

Embodiment 61. The method or web of any of the preceding embodiments, wherein the layer of electrochemically active material comprises single-walled carbon nanotubes or multi-walled carbon nanotubes.

Embodiment 62. The method or web of any of the preceding embodiments, wherein the layer of electrochemically active material comprises single-walled carbon nanotubes.

Embodiment 63. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises a metal, semi-metal, alloy, or oxide or nitride thereof capable of forming an alloy with lithium.

Embodiment 64 the method or web of any preceding embodiment, wherein the electrochemically active material layer comprises graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon/carbon composite, silicon/graphite blend, silicon oxide (SiO _x ) Porous silicon, intermetallic silicon alloy, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, lithium titanate, palladium, or combinations thereof.

Embodiment 65. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises aluminum, tin, or silicon, or an oxide thereof, a nitride thereof, a fluoride thereof, or an alloy thereof.

Embodiment 66. The method or web of any of the preceding embodiments, wherein the electrochemically active material layer comprises silicon or an alloy thereof or an oxide thereof.

Embodiment 67. The method or web of any of the preceding embodiments, wherein the conductive layer comprises a material suitable for use as a negative current collector layer, the electrochemically active material layer comprises an anode active material, and the conductivity of the conductive layer is substantially greater than the conductivity of the anode active material layer.

Embodiment 68. The method or web of any of the preceding embodiments, wherein the ratio of the conductivity of the conductive layer to the conductivity of the anode active material layer is at least 100:1.

Embodiment 69. The method or web of any preceding embodiment, wherein the ratio of the conductivity of the conductive layer to the conductivity of the anode active material layer is at least 500:1.

Embodiment 70. The method or web of any of the preceding embodiments, wherein the ratio of the conductivity of the conductive layer to the conductivity of the anode active material layer is at least 1,000:1.

Embodiment 71. The method or web of any of the preceding embodiments, wherein the ratio of the conductivity of the conductive layer to the conductivity of the anode active material layer is at least 5,000:1.

Embodiment 72. The method or web of any of the preceding embodiments, wherein the ratio of the conductivity of the conductive layer to the conductivity of the anode active material layer is at least 10,000:1.

Embodiment 73. The method or web of any of the preceding embodiments, wherein the web is a laminate comprising an electrochemically active layer and a conductive layer.

Embodiment 74. The method or web of any of the preceding embodiments, wherein the electrochemically active layer comprises an anode active material.

Embodiment 75. The method or web of any of the preceding embodiments, wherein the electrochemically active layer comprises a cathode active material.

Embodiment 76. The method or web of any of the preceding embodiments, wherein the laser machining comprises forming a plurality of cuts and perforations through the web.

Embodiment 77. The method or web of any of the preceding embodiments, wherein the strength of the machined web in the web direction is 10% to 75% of the strength of the unmachined web in the web direction.

Embodiment 78. The method or web of any of the preceding embodiments, wherein the strength of the machined web in the cross-web direction is 5% to 30% of the strength of the unmachined web in the cross-web direction.

Embodiment 79. The method or web of any of the preceding embodiments, wherein the alignment feature comprises a through hole extending through the web.

Embodiment 80. The method or web of any of the preceding embodiments, wherein the laser machining comprises forming a series of outer perforations and a series of inner perforations, the outer perforations having a lower breaking strength than the inner perforations.

Embodiment 81. The method or web of any preceding embodiment, wherein the laser machining comprises ablating an electrode joint region from each scribed electrode.

Embodiment 82. The method or web of any of the preceding embodiments, further comprising laser machining the web in the machine direction of the web.

Embodiment 83. The method or web of any of the preceding embodiments further comprising using information related to the registration features to position the laser beam during laser machining of the web.

Embodiment 84. The method or web of any of the preceding embodiments, wherein the laser machining comprises controlling a first laser device to laser machine the web in a cross-web direction and controlling a second laser device to laser machine the web in a machine-web direction.

Embodiment 85 the method or web of any preceding embodiment, further comprising applying a vacuum to the web during laser machining of the web.

Embodiment 86 the method or web of any preceding embodiment, further comprising detecting a defect in the scored member using a sensor.

Embodiment 87. The method or web of any of the preceding embodiments, further comprising marking the web using a marking device in a manner that indicates a defect detected in the scored member.

Embodiment 88 the method or web of any preceding embodiment, further comprising laser machining tie bars between the scored member groupings.

Embodiment 89. The method or web of any of the preceding embodiments, wherein the tie bars are defined by laser machining slits in a cross-web direction.

Embodiment 90. The method or web of any of the preceding embodiments, further comprising applying tension to the web in a cross-web direction prior to laser machining.

Embodiment 91. The method or web of any of the preceding embodiments, wherein the alignment feature is formed at a location remote from the scored member in the cross-web direction.

Embodiment 92. The method or web of any of the preceding embodiments further comprising leaving an unmachined portion of the web between the registration features and an outermost edge of the web in the cross-web direction.

Embodiment 93. The method or web of any of the preceding embodiments, wherein the non-machined portions extend across an entire length of the web in the web direction.

Embodiment 94 the method or web of any preceding embodiment, further comprising contacting the rotating brush with the web after laser machining.

Embodiment 95. The method or web of any of the preceding embodiments, wherein the laser machining process occurs while the web is moving in the machine direction of the web.

Embodiment 96. The method or web of any of the preceding embodiments, wherein the laser beam is controlled during laser machining to account for the speed at which the web travels in the machine direction of the web.

Embodiment 97 the method or web of any preceding embodiment, further comprising controlling the tension of the web in the longitudinal direction of the web during laser machining.

Embodiment 98. The method or web of any of the preceding embodiments, further comprising winding the laser-machined web with an onsert layer.

Embodiment 99 the method or web of any preceding embodiment, further comprising transporting the web in the longitudinal direction of the web after laser machining without releasing the scored member from the web.

Embodiment 100. The method or web of any of the preceding embodiments, wherein the alignment feature has a one-to-one ratio to the scored member.

Embodiment 101. The method or web of any of the preceding embodiments, wherein the weakened portion comprises a series of through cuts or perforations.

Embodiment 102. The method of any of the preceding embodiments, further comprising pressure balancing the web during formation of the discontinuous weakened portions.

Embodiment 103. The method or web of any of the preceding embodiments, wherein pressure balancing involves applying a fluid flow over the web.

Embodiment 104. The method or web of any of the preceding embodiments, wherein pressure balancing comprises applying fluid flows on opposite sides of the web.

Embodiment 105. The method or web of any of the preceding embodiments, wherein the alignment features are formed prior to laser machining.

Embodiment 106. The method or web of any of the preceding embodiments, wherein the alignment features are used to help form discontinuous weakened portions.

Embodiment 107 the method or web of any preceding embodiment, wherein the support surface comprises aluminum and the support surface dissipates thermal energy from the laser machining process.

Embodiment 108. The method or web of any of the preceding embodiments, wherein the laser machining is performed on a portion of the web above the opening of the support surface.

Embodiment 109. The method or web of any of the preceding embodiments, wherein controlling a portion of the web comprises controlling the web in a direction substantially parallel to a vertical axis of the laser beam.

Embodiment 110. The method or web of any of the preceding embodiments, wherein the support surface comprises a plurality of openings, and the forming of the weakened tear pattern and the forming of the series of alignment features are performed on respective portions of the web above different ones of the plurality of openings.

Embodiment 111 the method or web of any of the preceding embodiments, wherein controlling the tension of the web comprises maintaining the tension on the web at 500 grams force or less.

Claims (30)

1. A method for scoring groups of electrode structures in a web comprising a conductive layer having opposite front and back sides and an electrochemically active material layer on the front side, on the back side, or on both the front and back sides, the web having a web longitudinal direction and a web transverse direction, the web longitudinal direction and the web transverse direction being orthogonal to each other, the method comprising:

controlling tension of the web in the web longitudinal direction while forming a series of weakened tear patterns in the web longitudinal direction, in the web transverse direction, or in each of the web transverse direction and the web longitudinal direction, the weakened tear patterns inscribing members of an electrode structure group without releasing the inscribed members from the web, wherein each of the inscribed members is at least partially defined by a member of the series of weakened tear patterns adapted to facilitate separation of each of the inscribed members from the web by application of force; and

A series of alignment features are formed in the web, the alignment features being disposed in the cross-web direction or the machine-web direction relative to the scored members, the alignment features each being adapted to locate a scored member of a group of electrode structures in the web.

2. The method of claim 1, wherein the series of weakened tear patterns, or the series of alignment features, or the series of weakened tear patterns and the series of alignment features are formed by a laser.

3. The method of claim 1, wherein one or more rollers are used to control the tension of the web.

4. The method of claim 1, wherein the electrochemically active material layer is on only one of the front and back sides of the conductive layer.

5. The method of claim 1, wherein the electrochemically active material layer is on both the front and back sides of the conductive layer.

6. The method of claim 1, wherein the scored member of the electrode structure group has a length L _E Width W _E And height H _E Wherein W is _E Measured in a direction orthogonal to the front and back sides of the web and orthogonal to the longitudinal and transverse web directions and: (i) L (L) _E Measured in the cross-web direction and H _E Measured in the machine direction of the web, or (ii) L _E Measured in the longitudinal direction of the web, and H _E Measured in the cross-web direction, where L _E And W is equal to _E And H _E Is at least 5:1 (i.e., L) _E And W is equal to _E Is at least 5:1, and L _E And H is _E At least 5:1, respectively).

7. The method of claim 6, wherein H _E And W is equal to _E The ratio of (2) is at least 0.4:1, respectively.

8. The method of claim 1, wherein the conductive layer comprises a material suitable for use as a positive current collector layer or a negative current collector.

9. The method of claim 1, wherein the electrochemically active material layer comprises a cathode active material.

10. The method of claim 1, wherein controlling the tension of the web comprises maintaining the tension on the web at 500 grams force or less.

11. The method of claim 1, wherein the electrochemically active material layer comprises an anode active material.

12. A method for scoring groups of electrode structures in a web comprising a conductive layer having opposite front and back sides and an electrochemically active material layer on the front side, on the back side, or on both the front and back sides, the web having a web longitudinal direction and a web transverse direction, the web longitudinal direction and the web transverse direction being orthogonal to each other, the method comprising:

Supporting a portion of the web on a support surface, the support surface defining an opening;

forming a series of weakened tear patterns in the web that score members of an electrode structure group in the web longitudinal direction, in the web transverse direction, or in each of the web transverse direction and the web longitudinal direction without releasing the scored members from the web, wherein each of the scored members is at least partially defined by a member of the series of weakened tear patterns adapted to facilitate separation of each of the scored members from the web by application of a force; and

forming a series of alignment features in the web, the alignment features being disposed in the cross-web direction or the machine-web direction relative to the scored members, the alignment features each being adapted to locate the scored members of the electrode structure group in the web,

wherein at least one of forming a weakened tear pattern and forming a series of alignment features is performed on a portion of the web above an opening defined on the support surface.

13. The method of claim 12, wherein at least one of forming a weakened tear pattern and forming a series of alignment features comprises forming a plurality of cuts and perforations through the web.

14. The method of claim 12, wherein forming the weakened tear pattern and forming the series of alignment features comprises laser machining, and the strength of the machined web in the web direction is 10% to 75% of the strength of the unmachined web in the web direction.

15. The method of claim 14, wherein the strength of the machined web in the cross-web direction is 5% to 30% of the strength of the unmachined web in the cross-web direction.

16. The method of claim 14, wherein the laser machining comprises forming a series of outer perforations and a series of inner perforations, the outer perforations having a lower breaking strength than the inner perforations.

17. The method of claim 12, wherein the bearing surface comprises aluminum.

18. The method of claim 12, further comprising applying a vacuum to the web during the forming of the weakened tear pattern and during the forming of the series of registration features.

19. The method of claim 12, wherein the support surface comprises a plurality of openings, and forming the weakened tear pattern and forming the series of alignment features are performed on respective portions of the web above different ones of the plurality of openings.

20. The method of claim 12, wherein forming a weakened tear pattern and forming a series of alignment features comprises laser machining, wherein the method further comprises applying tension to the web in at least one cross-web direction prior to the laser machining or applying tension to the web in the machine-web direction during the laser machining.

21. The method of claim 20, further comprising leaving an unmachined portion of the web between the registration feature and an outermost edge of the web in the cross-web direction.

22. The method of claim 20, further comprising contacting a rotating brush with the web after laser machining.

23. A method for scoring groups of electrode structures or groups of electrode separator structures in a web comprising a web longitudinal direction, a web transverse direction orthogonal to the web longitudinal direction, and an electrically insulating layer, the method comprising: controlling the portion of the web to be laser machined to be within about +/-100 microns of a laser focus of the laser beam; laser machining the portion of the web in at least one of the cross-web direction and the machine-web direction to scribe members of the electrode structure groups or electrode separator structure groups in the web without releasing the scribed members from the web; and forming in the web an alignment feature adapted to locate in the web a member of the or each scribe of the group of electrode structures.

24. The method of claim 23, wherein controlling a portion of the web comprises controlling the web in a direction substantially parallel to a vertical axis of the laser beam.

25. The method of claim 23, wherein the laser machining is performed with a laser having a laser power in the range of 10 watts to 5,000 watts, the laser being a fiber laser, the laser having a laser pulse width type that can be at least one of the following pulse types: a continuous wave (cw) pulse type, a microsecond (μs) pulse type, a nanosecond (ns) pulse type, a picosecond (ps) pulse type, and a femtosecond (fs) pulse type, or a combination thereof.

26. The method of claim 23, wherein the alignment feature is used to assist in forming a discontinuous weakened portion.

27. The method of claim 23, wherein the strength of the machined web in the web direction is 10% to 75% of the strength of the unmachined web in the web direction.

28. The method of claim 23, wherein the laser machining is performed on a portion of the web above the opening of the support surface.

29. The method of claim 28, wherein the support surface comprises aluminum and dissipates thermal energy from a laser machining process.

30. The method of claim 23, further comprising applying tension to the web in the longitudinal direction of the web during laser machining.