Blue Laser Welding for Low-Resistance Copper and Aluminum Joints
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Solution Overview
Problem
Conventional infrared lasers struggle to produce high-quality, low-resistance welds between copper, aluminum, stainless steel, and nickel-plated materials due to low absorptivity, requiring high power or high brightness lasers, which result in narrow processing windows and difficulties with repeatability, control, and scalability.
Innovation Solution
The use of blue laser beams with wavelengths between 400 nm and 500 nm, which offer higher absorptivity for these materials, allowing for more robust and repeatable welding processes with lower power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional infrared lasers (wavelength > 700 nm) are used for welding metal pieces, then the laser can be delivered to the target, but the material absorptivity is low requiring very high power or high brightness lasers
Solution Approach 1:
The patent changes the laser wavelength parameter from infrared (>700 nm) to visible range (400-500 nm). This parameter change increases material absorptivity from low levels to 40-75%, eliminating the need for very high power lasers and expanding the processing window for reliable, repeatable welding of copper, aluminum, stainless steel, and nickel-plated materials.
2Reliability
If very high power or high brightness lasers are used to compensate for low absorptivity, then welding can be achieved, but the processing window becomes narrow making the operation difficult to control and repeat
Solution Approach 1:
By changing the laser wavelength to the visible range (400-500 nm), the patent achieves high material absorptivity (40-75%) without requiring extreme laser parameters. This creates a wider, more forgiving processing window that is easier to control and repeat, while maintaining consistent weld quality.
3Manufacturing precision
If conventional infrared lasers are used, then existing systems can be utilized, but welding of high reflectivity materials produces high resistivity joints with difficulty achieving low resistance connections
Solution Approach 1:
The patent changes the laser wavelength to visible range (400-500 nm) where high reflectivity materials like copper, aluminum, stainless steel, and nickel-plated materials exhibit high absorptivity (40-75%). This enables consistent production of low resistivity welds (0.1-250 mΩ) that meet stringent electrical connection requirements.
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
This approach enables the production of welds with resistivity ranging from 0.1 mΩ to 250 mΩ, providing greater control, higher tolerances, and improved reproducibility, addressing the limitations of infrared laser welding.
Implementation Method 1
the pieces of metal absorb from about 40% to about 75% of the laser beam
Data Source
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.