Protective-Coated Copper Nozzle for Stable Laser Welding
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Solution Overview
Problem
The copper nozzle used in laser welding of battery cell components is prone to ablation and oxidation due to reflected laser light, leading to poor welding effects and a reduced service life, necessitating frequent replacements.
Innovation Solution
A copper nozzle with a protective layer having a higher reflectance coefficient and melting point than copper is applied, which reduces laser absorption and deformation, ensuring stable gas guidance and easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a copper nozzle is used for laser welding, then good thermal conductivity is achieved, but the nozzle is prone to ablation and oxidation due to reflected laser light
Solution Approach 1:
The copper nozzle is coated with a protective layer having different material properties (higher melting point and oxid resistance) than the copper substrate. This composite structure combines the thermal conductivity of copper with the protective characteristics of the coating layer, resolving the contradiction between thermal performance and durability.
Solution Approach 2:
The protective layer changes the surface parameters of the copper nozzle by providing a surface with higher melting point and better oxid resistance while maintaining the underlying copper's thermal conductivity. This parameter differentiation at different levels (surface vs. bulk) resolves the contradiction.
2Use of energy by moving object
If a copper nozzle is used for laser welding, then efficient heat transfer is achieved, but ablation and deformation occur due to laser absorption
Solution Approach 1:
The protective layer acts as an intermediary between the laser and the copper nozzle. It has lower laser absorption and higher melting point than copper, thereby protecting the copper substrate from direct laser exposure while allowing efficient heat transfer to the workpiece through the thin coating layer.
3Productivity
If the copper nozzle surface is exposed to reflected laser light, then welding operations can proceed, but oxidation and ablation reduce welding quality
Solution Approach 1:
The protective layer is applied in advance to the copper nozzle surface before welding operations begin. This preliminary protective measure prevents oxidation and ablation during the welding process, ensuring consistent welding quality without interfering with productivity.
4Reliability
If a protective layer is applied to the copper nozzle, then service life is extended, but device complexity increases
Solution Approach 1:
A thin protective film or coating layer is applied to the copper nozzle surface. This thin layer provides the necessary protection against oxidation and ablation while maintaining a simple overall nozzle structure, minimizing the increase in device complexity.
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 protective layer extends the nozzle's service life, enhances welding stability, and improves the welding yield by minimizing ablation and deformation, facilitating efficient and reliable laser welding operations.
Implementation Method 1
a reflectance coefficient of the protective layer is greater than a reflectance coefficient of copper
Data Source
AI summary
A copper nozzle, a copper nozzle assembly, and laser welding equipment having the copper nozzle assembly are provided, where the copper nozzle is used for laser welding, the copper nozzle includes: a copper nozzle body, the copper nozzle body having a laser channel; and a protective layer, where the protective layer covers a surface of the copper nozzle body, a reflectance coefficient of the protective layer is greater than a reflectance coefficient of copper, and a melting point of the protective layer is greater than a melting point of copper, which can extend the service life of the copper nozzle and make cleaning of the copper nozzle convenient.