Battery Metal Bonding With Laser Etching to Remove Weld Spatter
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Solution Overview
Problem
Conventional laser welding of metal members in electrical energy storage devices results in the scattering of molten metal spatter, leading to potential short-circuits and the need for inefficient post-welding spatter removal.
Innovation Solution
A bonding method involving a laser welding step followed by an etching step with a lower output energy beam to form concave parts on the welding bonding surface, effectively removing scattered spatter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to bond metal members, then bonding strength is improved, but weld spatter scatters causing short-circuit risks and requiring additional removal steps
Solution Approach 1:
The patent converts the harmful weld spatter into a beneficial etching effect by using the same laser source to create desired surface concave features. The spatter that would normally be considered waste or contamination is instead utilized to form the etched pattern, eliminating the need for separate spatter removal operations.
Solution Approach 2:
The patent performs the etching action immediately after welding while the surface is still hot and the spatter is present. This preliminary action captures the spatter before it can cause short-circuits, and uses it to create the etched pattern that will later serve functional purposes.
2Reliability
If weld spatter is removed by conventional methods, then short-circuit risks are reduced, but manufacturing time and complexity increase
Solution Approach 1:
The patent merges the welding process and the etching process into a single integrated operation. By using the laser welding beam to simultaneously create both the weld bond and the etched pattern, the patent eliminates separate spatter removal steps, thereby improving manufacturing efficiency while maintaining electrical connection reliability.
Solution Approach 2:
The laser beam is given multiple functions: it serves both as the welding energy source and as the etching tool. This multi-functionality allows the system to achieve both bonding and surface treatment in one operation, improving productivity without compromising reliability.
3Reliability
If additional etching step is added to remove spatter, then weld spatter remaining is reduced, but process complexity increases
Solution Approach 1:
The patent combines the welding function and etching function into a single laser processing step. By adjusting laser parameters such as power, pulse duration, and scanning speed, the same laser system performs both welding and etching, thereby reducing process complexity while maintaining high reliability through effective spatter management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method efficiently reduces the presence of weld spatter, enhancing the reliability and stability of electrical connections in the devices.
Implementation Method 1
a laser welding step of irradiating a boundary portion between a first member made of a metal and a second member made of a metal with laser, thereby forming a welding bonding part
Implementation Method 2
an etching step of irradiating a surface of the welding bonding part and its peripheral part with an energy beam with lower output than an output in the laser welding step, thereby forming a plurality of concave parts with a substantially circular shape at the surface of the welding bonding part and its peripheral part
Data Source
AI summary
A bonding method disclosed herein includes: a laser welding step of irradiating a boundary portion between a first member made of a metal and a second member made of a metal with laser, thereby forming a welding bonding part; and an etching step of irradiating a surface of the welding bonding part and its peripheral part with an energy beam with lower output than an output in the laser welding step, thereby forming a plurality of concave parts with a substantially circular shape at the surface of the welding bonding part and its peripheral part.