Laser Cleaning Battery Cell Bonding Areas

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Solution Overview

Problem

Current methods for preparing battery components for wire bonding are inefficient, as they require extensive surface preparation time and use of expensive chemicals, and do not effectively streamline the cleaning process for creating bonding areas on battery cells and bus bars.

Innovation Solution

A method involving laser cutting and cleaning to create bonding areas on battery cells and bus bars, utilizing a laser system to remove contaminants and expose clean surfaces for wire bonding, with a vision system for precise detection and positioning of the bonding areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional chemical cleaning methods are used to prepare bonding areas on battery cells and bus bars, then the surfaces can be cleaned of contaminants, but the process requires extensive surface preparation time and uses expensive chemicals

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidsurface preparation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces traditional chemical cleaning methods with laser cleaning technology. The laser beam directly ablates contaminants from the bonding areas on battery cells and bus bars, eliminating the need for chemical solutions and extensive manual preparation time while maintaining effective cleaning results

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the cleaning parameter from chemical concentration and contact time to laser power, pulse duration, and scanning speed. By adjusting these laser parameters, the system achieves effective contaminant removal in seconds without the time-consuming chemical soaking and multiple rinsing steps required by traditional methods

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional chemical cleaning methods are used to prepare bonding areas, then contaminants can be removed, but expensive chemicals and consumables are required

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidchemical consumables

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent substitutes chemical cleaning agents with a laser beam as the cleaning mechanism. The laser energy directly vaporizes and removes contaminants through ablation, eliminating the need for expensive chemical solutions, solvents, and associated consumables like wipes and containers

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser cleaning system is self-contained and does not require external chemical supplies. The laser beam itself performs the cleaning function through its energy, and the ablated material is removed by assist gas or vacuum, making the process independent of chemical consumables

Inventive Principle:

Principle #25Self-service

3Productivity

If laser cleaning is used to create bonding areas on battery cells and bus bars, then surface preparation time is reduced and chemicals are eliminated, but precise positioning and detection of bonding areas are required

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidbonding area detection accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent introduces a vision system as an intermediary between the laser cleaning process and the wire bonding operation. The vision system captures images of the bonding areas, processes the visual data to locate and dimension the cleaned surfaces, and provides this information to the wire bonding system for precise positioning

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The vision system provides real-time feedback about the actual position and dimensions of the laser-cleaned bonding areas. This feedback allows the system to adjust the wire bonding parameters and positioning accordingly, ensuring accurate wire placement even with variations in laser cleaning results

Inventive Principle:

Principle #23Feedback

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 significantly reduces surface preparation time, eliminates the need for expensive chemicals, and ensures efficient electrical connections by creating precise and clean bonding areas on battery cells and bus bars, enhancing the manufacturing efficiency of battery packs.

Implementation Method 1

laser cleaning the portion of the bus bar to form a second bonding area on the bus bar

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

laser cutting away a portion of the sleeve surrounding the battery cell

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20230011238A1Laser cleaning battery components

Publication Date: 2023.01.12 MILWAUKEE ELECTRIC TOOL CORP

AI summary

A battery pack including a supporting structure, a battery cell housed within the supporting structure, a sleeve partially surrounding the battery cell, a bus bar, and a wire. The sleeve extends over a portion of a first end of the battery cell and has a laser-cut cutaway portion exposing a laser-cleaned first bonding area of the first end of the battery cell. The laser-cleaned first bonding area is positioned adjacent to an outer perimeter of the first end of the battery cell. The bus bar has a laser-cleaned second bonding area. The wire is bonded to the first and second laser-cleaned bonding areas to electrically connect the battery cell to the bus bar.