Laser Welding Electrode Assembly Spot Pattern
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Solution Overview
Problem
The existing laser welding methods for electrode assemblies in secondary batteries result in a large weld portion and deteriorated welding quality due to the formation of predetermined matrix-shaped welded spots, which are difficult to reduce and maintain high quality.
Innovation Solution
A welding method that forms a pattern of first and second welded spots, where the second spots are misaligned perpendicularly to the first spots, with specific gaps and overlaps to minimize the weld portion and enhance welding quality, using a jig to press objects in close contact and a laser to create these spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a predetermined matrix shape of welded spots is formed, then welding coverage is ensured, but weld portion size increases and welding quality deteriorates
Solution Approach 1:
The welding pattern is segmented into multiple rows of welded spots arranged in a non-matrix configuration. Each row contains welded spots spaced at specific intervals, creating a distributed pattern that reduces concentration of weld material while ensuring adequate coverage across the bonding surface.
Solution Approach 2:
The welded spots are arranged in an asymmetric non-matrix pattern rather than a regular grid. The spacing between spots varies along different directions, with gaps controlled to be greater than or equal to the spot radius, creating an optimized distribution that minimizes total weld portion area while maintaining bonding integrity.
2Quantity of substance
If welded spots are formed in a matrix shape, then welding coverage is ensured, but weld portion size increases
Solution Approach 1:
The welding pattern transitions from a two-dimensional matrix arrangement to a multi-row linear arrangement with controlled spacing. By organizing spots into distinct rows with specific gap distances, the pattern achieves adequate coverage without the excessive material concentration inherent in matrix configurations.
Solution Approach 2:
The spacing parameters between welded spots are optimized to be greater than or equal to the spot radius in specific directions. This parameter control reduces the total area occupied by weld portions while maintaining sufficient coverage, directly addressing the contradiction between coverage quantity and area consumption.
3Quantity of substance
If welded spots are closely arranged, then welding coverage improves, but welding quality deteriorates
Solution Approach 1:
Different spacing requirements are applied in different directions and locations. Gaps between welded spots are controlled to be greater than or equal to the spot radius in directions perpendicular to the rows, while spacing along the rows follows different criteria. This localized quality control ensures adequate coverage without compromising welding quality through excessive proximity.
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 reduces the weld portion size, improves welding quality, and increases the energy density and electrical capacity of the electrode assembly by preventing excessive overlap and maintaining high tensile strength.
Implementation Method 1
irradiating the plurality of objects with laser to form a plurality of welded spots
Data Source
AI summary
A welding method includes pressing multiple objects together by a jig and irradiating the objects with laser to form multiple welded spots. The welded spots may include multiple first welded spots formed in a first direction and multiple second welded spots formed in the first direction and misaligned with the first welded spots in a second direction which is perpendicular to the first direction. A gap between the center of each of the first welded spots and the center of each of the second welded spots in the second direction. Another gap between the first welded spots in the first direction. And a gap between the second welded spots in the first direction may be greater than or equal to the radius of the second welded spot and less than or equal to a value of about 1 mm plus a diameter of the second welded spot.