US 12,447,532 B2
Systems and methods for laser additive manufacturing for structured battery electrodes
Jianchao Ye, Tracy, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Apr. 6, 2022, as Appl. No. 17/714,599.
Prior Publication US 2023/0321725 A1, Oct. 12, 2023
Int. Cl. B22F 12/41 (2021.01); B22F 1/105 (2022.01); B22F 10/16 (2021.01); B22F 12/49 (2021.01); B22F 12/53 (2021.01); B22F 12/58 (2021.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/10 (2020.01); B33Y 70/10 (2020.01); B33Y 80/00 (2015.01)
CPC B22F 10/16 (2021.01) [B22F 1/105 (2022.01); B22F 12/41 (2021.01); B22F 12/49 (2021.01); B22F 12/53 (2021.01); B22F 12/58 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/10 (2020.01); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12); B22F 2301/052 (2013.01); B22F 2302/40 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A system for making an electrically conductive battery component using a conveyor system having a plurality of spaced apart rollers, the system comprising:
a continuous, flexible, planar, grounded metal layer forming a build plane and further being configured to be entrained around the plurality of spaced apart rollers of the conveyor system, and further forming a planar metal substrate for supporting powder of a first material directly thereon and adapted to be cut, removed from the plurality of spaced apart rollers, such that the continuous, flexible, planar metal layer is able to be used as a support structure during a sintering operation, and also as a component which forms a structural portion of the electrically conductive battery component;
an electrostatic powder deposition component for applying a powder of a second material different from the first material, and which includes an active material, carbon black and a binder mixed in a predetermined composition, to form a powder layer, directly on the planar metal substrate, which is attracted to the grounded metal layer;
a laser configured to generate a laser beam to selectively sinter portions of the powder layer using a predetermined beam scanning pattern, such that spaced apart linear traces of the powder layer are sintered sequentially by the laser beam as the rollers are controlled to move the flexible, planar metal layer in a sequential operation, to form a finished material layer having an electrically conductive connection between the continuous, flexible, planar metal layer and the sintered portions of the powder layer; and
a subsystem for removing portions of the powder layer that are not sintered by the laser to leave a planar finished material layer having structural features with an engineered height, thickness and spacing.