# US 2025/0083259 A1 · Laser cutting mechanism and method for manufacture of an electrode

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- Number: US 2025/0083259 A1
- Document ID: US20250083259A1
- Status: Published application
- Kind: A1
- Application number: 18/882,321
- Filed: 2024-09-11
- Published: 2025-03-13
- Earliest claimed: 2023-09-11
- Assignees: Solid Power Operating, Inc.
- Applicants: Solid Power Operating, Inc.
- Inventors: David A. TELEP; Uday KASAVAJJULA
- Web page: https://patentgrep.com/patent/US20250083259A1

## CPC

- B23K 26/38: by boring or cutting
- B23K 26/0622: by shaping pulses
- B23K 26/142: for the removal of by-products
- B23K 2101/36: Electric or electronic devices
- Y02E 60/10: Energy storage using batteries
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Systems and methods of using a laser cutting device to cut an electrode laminate for a battery. The laser cutter may super heat and volatilize the various components of the layers of the electrode stack. The laser cutter may be programmed or otherwise controlled to direct its laser to cut the electrode stack into any shape. Further, as the laser cutter super heats the materials within the layer(s), the material may volatilize or ablate and be removed from the environment with simple vacuum systems, thereby reducing or eliminating metal shards and other contaminants that may be generated through conventional cutting procedures that damage or short-circuit the electrode. This “cauterization” process may also generate a unique pattern or composition of oxides and hydroxides of the electrode that is identifiable through a chemical mapping process to uniquely identify, or “fingerprint”, the electrode based on the chemical make-up of the cut electrode stack.

## Claims

### Claim 1

A method for cutting a battery electrode, the method comprising:
laminating an electrode stack comprising a plurality of layers using a pressing device, wherein the pressing device laminates a solid-state electrolyte (SSE)-containing layer to a conductive foil; and
removing, using a laser cutting device, a portion of the electrode stack.

### Claim 2 (depends on 1)

The method of claim 1, wherein the laser cutting device melts a plurality of components of the plurality of layers of the electrode stack to remove the portion from the electrode stack.

### Claim 3 (depends on 2)

The method of claim 2, wherein melting the SSE-containing layer causes oxidation of the SSE-containing layer along a cut edge of the portion of the electrode stack.

### Claim 4 (depends on 3)

The method of claim 3, wherein the oxidation of the SSE-containing layer along the cut edge of the portion of the electrode stack reduces a reaction of the SSE-containing layer to ambient moisture.

### Claim 5 (depends on 3)

The method of claim 3, wherein the electrode stack comprises a higher concentration of oxidation at the cut edge of the portion of the electrode stack than a middle portion of the electrode stack.

### Claim 6 (depends on 1)

The method of claim 1 further comprising:
controlling a position of the laser cutting device to remove a shaped portion of the electrode stack.

### Claim 7 (depends on 1)

The method of claim 1 further comprising:
controlling an energy profile of a laser beam generated from the laser cutting device, the energy profile comprising at least one of a temperature of the laser beam, a position of the laser beam, or a pulse frequency of the laser beam.

### Claim 8 (depends on 1)

The method of claim 1 further comprising:
removing, using a vacuuming device, a byproduct of the electrode stack caused by the removing of the portion of the electrode stack.

### Claim 9 (depends on 8)

The method of claim 8, wherein the vacuuming device further reduces a temperature of the portion of the electrode stack.

### Claim 10 (depends on 1)

The method of claim 1, wherein the electrode stack comprises at least one SSE layer, an upper electrode layer, the conductive foil, and a lower electrode layer.

### Claim 11 (depends on 1)

The method of claim 1, wherein the pressing device is a calendar press comprising a first roller and a second roller, the first roller oriented above the second roller and separated by a pressing gap.

### Claim 12 (depends on 1)

The method of claim 1, wherein removing the portion of the electrode stack comprises cutting through the plurality of layers of the electrode stack to generate a defined shape of an electrode from the electrode stack.

### Claim 13

A system for manufacturing an electrode of a battery, the system comprising:
a pressing device laminating an electrode stack comprising a solid-state electrolyte (SSE)-containing layer and a conductive foil; and
a laser cutting device producing a laser beam to cut a portion of the electrode stack into a shaped electrode for the battery.

### Claim 14 (depends on 13)

The system of claim 13, wherein the laser cutting device melts a plurality of components of the SSE-containing layer and the conductive foil to remove the portion from the electrode stack.

### Claim 15 (depends on 14)

The system of claim 14, wherein melting the SSE-containing layer causes oxidation of the SSE-containing layer along a cut edge of the portion of the electrode stack.

### Claim 16 (depends on 15)

The system of claim 15, wherein the oxidation of the SSE-containing layer along the cut edge of the portion of the electrode stack reduces a reaction of the SSE-containing layer to ambient moisture.

### Claim 17 (depends on 13)

The system of claim 13 further comprising:
a controller in communication with the laser cutting device controlling a position of the laser cutting device to remove a shaped portion of the electrode stack.

### Claim 18 (depends on 17)

The system of claim 17, wherein the controller further controls an energy profile of the laser beam generated from the laser cutting device, the energy profile comprising at least one of a temperature of the laser beam, a position of the laser beam, or a pulse frequency of the laser beam.

### Claim 19 (depends on 13)

The system of claim 13 further comprising:
a vacuuming device removing a byproduct of the electrode stack caused by the removing of the portion of the electrode stack.

### Claim 20 (depends on 13)

The system of claim 13, wherein the electrode stack comprises at least one SSE layer, an upper electrode layer, the conductive foil, and a lower electrode layer.