Battery Laser Welding with Peak-Base Power Heat Control

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Solution Overview

Problem

Conventional welding devices using continuous wave (CW) laser welding methods often result in welding defects due to excessive heat input energy accumulation in the welding portion, particularly when welding battery module components.

Innovation Solution

A welding device and method that utilize a laser power control unit to alternately irradiate a welding portion with peak power and base power lasers, maintaining the welding portion in a liquid state to prevent excessive heat accumulation and minimize defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If continuous wave (CW) laser welding method is used, then welding speed and productivity are maintained, but excessive heat input energy accumulation occurs causing welding defects

Engineering Contradiction:

Improvewelding speedVSAvoidwelding quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies periodic action by switching the laser irradiation between peak power and base power states in a controlled cycle. The laser irradiation unit alternates between high-power peak irradiation (for deep penetration and keyhole formation) and lower-power base irradiation (for heat control), creating a periodic welding process that prevents excessive heat accumulation while maintaining welding speed and productivity.

Inventive Principle:

Principle #19Periodic action

2Manufacturing precision

If peak power laser irradiation is applied to form keyhole, then deep penetration welding is achieved, but excessive heat input causes welding defects

Engineering Contradiction:

Improvepenetration depthVSAvoidheat input energy accumulation

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent uses periodic action to alternate between peak power irradiation (for keyhole formation and deep penetration) and base power irradiation (for heat control). This periodic switching allows the welding portion to achieve deep penetration during peak power phases while preventing excessive heat accumulation during base power phases, thereby eliminating welding defects.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent applies parameter changes by dynamically adjusting the laser power parameter between two distinct levels (peak power and base power). The control unit modifies the laser irradiation parameters based on the welding process requirements, switching between high power for penetration and lower power for heat management, thus achieving both deep penetration and heat control.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If laser power is reduced to minimize heat accumulation, then welding defects are reduced, but welding speed and productivity decrease

Engineering Contradiction:

Improvewelding qualityVSAvoidwelding speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent resolves this contradiction through periodic action by cycling between peak power and base power irradiation. During peak power phases, deep penetration welding occurs at high speed; during base power phases, heat accumulation is controlled. This periodic alternation maintains overall welding speed and productivity while preventing defects that would occur with continuously reduced power.

Inventive Principle:

Principle #19Periodic action

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 approach effectively minimizes welding defects by controlling heat input, maintaining high laser absorption rates, and sustaining welding speed and productivity comparable to traditional methods.

Implementation Method 1

a laser irradiation unit (100) configured to irradiate a laser

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the laser with the base power may have an output capable of allowing the welding portion to remain in a liquid state

Methodology Applied

Scientific EffectLaser absorption: Absorption (EM radiation)

Implementation Method 3

a welding device includes a laser irradiation unit and a laser power control unit configured to control the laser irradiation unit to irradiate the laser with a peak power and the laser with a base power to a welding portion

Methodology Applied

Scientific EffectLaser beam welding: Laser Beam Welding

Data Source

PatentUS20250128353A1Welding device, welding method, battery manufacturing device and vehicle manufacturing device

Publication Date: 2025.04.24 LG ENERGY SOLUTION LTD

AI summary

Discussed are a welding device and a welding method that may improve welding efficiency during a battery manufacturing process, and a battery manufacturing device and a vehicle manufacturing device including such a welding device. A welding device can include a laser irradiation unit configured to irradiate a laser; and a laser power control unit configured to control the laser irradiation unit to irradiate the laser with the peak power and the laser with the base power to a welding portion.