Blue Laser Welding of Thin Conductors for Precise Battery Joints
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Solution Overview
Problem
Conventional infrared lasers struggle to produce consistent, high-quality welds between copper, aluminum, stainless steel, and nickel-plated materials due to low absorptivity, requiring high power or high brightness, which leads to narrow processing windows and difficulties in achieving high tolerances and uniformity in applications like battery and energy storage systems.
Innovation Solution
Using blue laser beams with wavelengths between 400 nm to 500 nm, which have higher absorptivity for these materials, allowing for better energy coupling and enabling lower power welding with improved control and reproducibility, reducing the risk of runaway processes and enabling the welding of thin and thick materials with greater precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If infrared welding is used for wire bonding, then welding speed is improved, but welding precision and control are worsened due to long wavelength limitations
Solution Approach 1:
The patent changes the wavelength parameter from infrared (long wavelength) to visible light (short wavelength). This parameter change enables both high-speed welding and precise control, resolving the contradiction between welding speed and welding precision that plagues infrared welding systems.
2Adaptability or versatility
If conventional welding methods are used, then material compatibility is limited, but process versatility is worsened
Solution Approach 1:
The visible light welding system is designed to weld multiple material types (gold, aluminum, copper, tungsten, molybdenum, nickel) and bond to various substrates (gold, aluminum, copper, tungsten, molybdenum, nickel, silicon, glass, ceramic, plastic) using a single process platform, achieving universal material compatibility without proportionally increasing device complexity.
3Speed
If high power density is applied for welding, then welding speed is improved, but heat-affected zone and damage risk are worsened
Solution Approach 1:
The patent changes the light wavelength parameter to visible range (shorter than infrared), which allows achieving high power density for fast welding while creating a smaller heat-affected zone. The shorter wavelength enables more precise energy localization, reducing thermal damage to surrounding materials.
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 blue laser welding method achieves robust, low-resistance, high-fatigue-cycle joints with improved mechanical and electrical characteristics, enhancing the reproducibility and reliability of welds in energy storage and electronics applications, while reducing costs and complexity.
Implementation Method 1
The methods described herein relate to visible light laser welding of wire to a substrate
Implementation Method 2
visible light laser welding of wire to a substrate, including gold, aluminum, copper, tungsten, molybdenum, and nickel wires to various substrates
Data Source
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AI summary
A visible light laser system and operation for welding materials together. A blue laser system and operation for welding conductive elements, and in particular thin conductive elements, together for use in energy storage devices, such as battery packs.