Laser Welding Battery Foils to Tabs Using Clamping System

Solution Overview

Problem

Ultrasonic welding of battery foils to tabs suffers from inconsistencies in weld quality, resonance, mechanical and thermal deformation, and adhesion issues, necessitating an alternative method for creating a strong and efficient tab-to-foil weld.

Innovation Solution

A clamping system and method using laser welding to join battery foils to a battery tab, where the foils and tab are clamped together using movable arms with aligned slots to receive a laser beam, eliminating gaps and avoiding ultrasonic welding shortcomings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ultrasonic welding is used to join battery tabs to battery foils, then the welding process can be performed, but weld quality inconsistency and mechanical deformation occur

Engineering Contradiction:

Improveweld quality consistencyVSAvoidweld thickness uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces the ultrasonic welding mechanism (mechanical vibration-based) with a laser welding system. The laser beam delivers energy directly to the battery foil and tab interface, eliminating the mechanical vibration process that causes resonance and deformation. This substitution of the welding mechanism fundamentally resolves the inconsistency issues by providing controlled, localized heating without mechanical contact or vibration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the welding parameters from ultrasonic vibration frequency and amplitude to laser power, focal position, and welding speed. These parameter changes enable precise control over the welding process, allowing consistent weld quality and uniform penetration depth without the variability inherent in ultrasonic welding processes.

Inventive Principle:

Principle #35Parameter changes

2Strength

If ultrasonic welding is used to join battery tabs to battery foils, then the welding process can be performed, but mechanical and thermal deformation occurs

Engineering Contradiction:

Improvetab-to-foil weld strengthVSAvoidfoil and tab deformation

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent replaces the ultrasonic welding mechanism (mechanical vibration-based) with a laser welding system. The laser beam delivers energy directly to the battery foil and tab interface, eliminating the mechanical vibration process that causes resonance and deformation. This substitution of the welding mechanism fundamentally resolves the inconsistency issues by providing controlled, localized heating without mechanical contact or vibration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a clamping system as an intermediary between the laser welding process and the battery components. The clamping system holds the battery foil and tab in precise alignment and maintains constant pressure during welding, preventing deformation while ensuring consistent contact between the components being joined.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If ultrasonic welding is used to join battery tabs to battery foils, then the welding process can be performed, but adhesion to the tool occurs

Engineering Contradiction:

Improvewelding process simplicityVSAvoidtool adhesion

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the ultrasonic welding mechanism (mechanical vibration-based) with a laser welding system. The laser beam delivers energy directly to the battery foil and tab interface, eliminating the mechanical vibration process that causes resonance and deformation. This substitution of the welding mechanism fundamentally resolves the inconsistency issues by providing controlled, localized heating without mechanical contact or vibration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method produces a structurally strong and efficient tab-to-foil weld with improved consistency and reduced risk of deformation, enhancing the reliability of battery cell connections.

Implementation Method 1

laser welding the plurality of battery foils to the battery tab

Methodology Applied

Scientific EffectLaser beam welding: Laser Beam Welding

Implementation Method 2

a laser beam is received by the first slot and the second slot to join the plurality of battery foils to the battery tab

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS11095004B2Clamping system and method for laser welding battery foils to a battery tab

Publication Date: 2021.08.17 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for laser welding a plurality of battery foils to a battery tab that does not include ultrasonic welding and includes clamping the plurality of battery foils and the battery tab together. Each of the plurality of battery foils has a thickness that is between 0.004 millimeters and 0.03 millimeters. The battery tab has a thickness that is between 0.1 millimeters and 0.5 millimeters. The method further includes laser welding the plurality of battery foils to the battery tab.