Electrochemical Device Components With Oxide Weld Regions

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Solution Overview

Problem

Laser welding of metal components in electrochemical devices is challenging due to light reflection, and existing methods do not efficiently address the need for improved welds that maintain electrical conductivity.

Innovation Solution

A method involving the removal of a metal oxide layer to define weld regions with a higher oxygen concentration for laser welding, while maintaining exposed regions with lower oxygen concentrations for enhanced electrical conductivity, allowing for efficient welding and current conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser welding is used to weld metal components, then the welding process is non-contact and does not deform welded parts, but the metal components reflect a large portion of the laser light making welding difficult

Engineering Contradiction:

Improvewelding process easeVSAvoidweld quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by creating distinct regions on the metal component surface: a weld region with metal oxide layer that has high laser absorption, and an exposed region with removed oxide that has high electrical conductivity. This local differentiation allows the weld region to efficiently absorb laser energy for reliable welding while the exposed region maintains electrical conductivity for current flow.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the surface parameter (oxide concentration) to control laser absorption. By removing the metal oxide layer from the exposed region while retaining it in the weld region, the surface optical properties are modified. The weld region with oxide has higher absorption of laser light, enabling reliable laser welding, while the exposed region with removed oxide maintains electrical conductivity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If metal oxide layer is present on the surface, then laser absorption is improved for welding, but electrical conductivity is reduced

Engineering Contradiction:

Improveweld qualityVSAvoidelectrical conductivity

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent segments the component surface into functionally distinct regions: a weld region where the metal oxide layer is retained to ensure laser absorption and welding quality, and an exposed region where the oxide layer is removed to ensure electrical conductivity. This segmentation allows each region to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

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 successful laser welding of electrochemical device components by reducing light reflection and ensuring efficient electrical conductivity through the welds, improving the overall efficiency and performance of the welding process.

Implementation Method 1

contacting at least one of the weld regions with a laser while using the laser to laser weld the components together along the seam

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

the metal components reflect a large portion of the laser light... the surface of the weld region includes the metal oxide... the surface of the exposed region includes the metal oxide at a lower concentration

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Data Source

PatentUS8637787B1Electrochemical device components having weld regions

Publication Date: 2014.01.28 QUALLION LLC

AI summary

Formation of an electrochemical device includes removing a layer of a metal oxide from battery components so as to define a weld region and an exposed region on the components. A surface of the weld region includes the metal oxide and a surface of the exposed region includes the metal oxide at a lower concentration than the weld region. The method also includes arranging the components such that a seam is defined between the components with weld regions positioned on opposing sides of the seams. The method further includes contacting at least one of the weld regions with a laser while laser welding the components together along the seam.