Method and device for cutting a multilayer assembly composed of a plurality of thin films and comprising a thin film electrochemical generator or a component part thereof

• US 5,250,784 A
• Filed: 10/24/1991
• Issued: 10/05/1993
• Est. Priority Date: 01/30/1990
• Status: Expired due to Term

• Current Assignee: Societe Nationale Elf Aquitaine (Cook Composites and Polymers), Hydro-Quebec (Province of Québec)
• Original Assignee: Societe Nationale Elf Aquitaine (Cook Composites and Polymers), Hydro-Quebec (Province of Québec)
• Inventors: Kapfer, Bruno, Muller, Daniel
• Primary Examiner(s): Albritton, C. L.
• Application Number:
  US07/768,551
• Time in Patent Office: 712 Days
• Field of Search: 219/121.67, 219/121.72, 219/121.84
• US Class Current: 219/121.72
• CPC Class Codes: B23K 2103/08 Non-ferrous metals or alloys
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 2103/12 Copper or alloys thereof
• CPC Class Codes: B23K 2103/16 Composite materials , e.g. fibre reinforced
• CPC Class Codes: B23K 2103/172 wherein at least one of the layers is non-metallic
• CPC Class Codes: B23K 2103/42 Plastics B23K2103/16 takes precedence
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/123 in an atmosphere of particular gases
• CPC Class Codes: B23K 26/40 taking account of the properties of the material involved
• CPC Class Codes: H01M 6/181 with polymeric electrolytes
• CPC Class Codes: H01M 6/188 Processes of manufacture

Abstract

At least one laser beam is focused on one side of an assembly to be cut at a point on the side which is part of the cutting profile and which is called the point of impact of the beam on side side, in order to cause at that point a disintegration of the material of the assembly. The laser beam is moved in relation to the assembly so that the impact point describes a trajectory which corresponds to the desired cutting profile, while maintaining a controlled atmosphere in the area around the impact point. Uses particularly include cutting solid polymer electrolyte lithium thin film electrochemical generators, or cutting precursors of such generators.

Claims

1. A process for carrying out the cutting, to a desired shape, of a multilayer assembly selected from the group consisting of a thin layer electrochemical generator and a constituent part of such a generator, said multilayer assembly comprising a plurality of thin layers at least one of which is selected from the group consisting of a metal ribbon and a macromolecular material containing layer, said process comprising the steps of:

focusing at least one laser beam on a face of the assembly to be cut, at a point on said cancelled face lying on the outline to be cut and termed point of impact and said beam on said face, so as to provide at said point a disintegration of the material of said assembly;

driving the laser beam in a relative movement with respect to the assembly to be cut such that said point of impact describes a trajectory corresponding to the outline to be cut out, while maintaining a controlled atmosphere in a zone surrounding said point of impact; and

selecting as the controlled atmosphere a reactive atmosphere which reacts with at least one of the components of the multilayer assembly in order to form a protective layer on a slice of the cut part of the assembly.

2. Process according to claim 1, wherein the relative movement of the laser beam with respect to the assembly to be cut is produced either by keeping the laser beam immobile and moving the assembly to be cut or by moving the laser beam and keeping the assembly to be cut immobile, or by moving both the laser beam and the assembly to be cut.

3. Process according to claim 1 or 2, wherein a continuous laser beam or a pulsed laser beam is used.

4. Process according to claim 3, wherein the laser beam is emitted by a gas laser source, a solid laser source, a semiconductor laser source or an organic dye laser source.

5. Process according to claim 3, wherein the laser beam is emitted by a gas laser source, having a power of less than 1000 W.

6. Process according to claim 5, wherein the cutting speed, which corresponds to the speed of relative movement of the point of impact of the laser beam on the face of the assembly to be cut, has a value ranging from about 1 cm/s to 1 m/s.

7. Process according to claim 1, wherein the reactive controlled atmosphere contains a controlled amount of a gaseous oxidizing agent, the amount being chosen so as to permit the formation of the chemical compound or compounds making up the desired protective layer without the reactive atmosphere becoming totally oxidizing.

8. Process according to claim 7, wherein the multilayer assembly to be cut is a lithium-based electrochemical generator in the form of thin layers containing solid polymer electrolyte or a constituent part of such a generator.

9. A process according to claim 1, wherein said protective layer is electronically insulating, ionically insulating or both.

10. A process according to claim 5, wherein the gas laser source is a CO₂ laser source having a power of between 0.5 and 600 W.

11. A process for carrying out the cutting, to a desired shape, of a multilayer assembly selected from the group consisting of a lithium-based thin layer electrochemical generator containing solid polymer electrolyte and a lithium-containing precursor of such a generator, said process comprising the steps of:

focusing at least one laser beam on a face of the assembly to be cut, at a point on said face lying on the outline to be cut and termed point of impact of said beam of said face, so as to provide at said point of disintegration of the material of said assembly;

driving the laser beam in a relative movement with respect to the assembly to be cut such that said point of impact describes a trajectory corresponding to the outline to be cut out, while maintaining a controlled atmosphere in a zone surrounding said point of impact; and

selecting as the controlled atmosphere a reactive atmosphere consisting in total or in part of CO₂, which reacts with the lithium in the multilayer assembly at the point of cutting to form a protective layer of electrochemically inert lithium carbonate on a slice of the cut part of the assembly.

12. A process according to claim 11, wherein the reactive atmosphere consists of CO₂ alone.

13. A process according to claim 11, wherein the reactive atmosphere consists of an inert gas containing an amount of CO₂ controlled to form the protective layer of lithium carbonate.

14. A process according to claim 11 or 13, wherein the reactive atmosphere containing CO₂ also includes oxygen in a concentration so selected to permit the formation of the protective layer of lithium carbonate without said atmosphere becoming totally oxidizing.

15. A process according to claim 11, wherein the relative movement of the laser beam with respect to the assembly to be cut is produced either by keeping the laser beam immobile and moving the assembly to be cut or by moving the laser beam and keeping the assembly to be cut immobile, or by moving both the laser beam and the assembly to be cut.

16. A process according to claim 11, wherein a continuous laser beam or a pulsed laser beam is used.

17. A process according to claim 16, wherein the laser beam is emitted by a gas laser source, a solid laser source, a semiconductor laser source or an organic dye laser source.

18. A process according to claim 16, wherein the laser beam is emitted by a gas laser source having a power of less than 1000 W.

19. A process according to claim 18, wherein the cutting speed, which corresponds to the speed of relative movement of the point of impact of the laser beam on the face of the assembly to be cut, has a value ranging from about 1 cm/s to 1 m/s.

20. A process according to claim 18, wherein the gas laser source is a CO₂ laser source having a power of between 0.5 and 600 W.