Laser Welding Splash Guard With Local Spatter Extraction
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Solution Overview
Problem
Existing laser welding processes for battery cell contact elements suffer from contamination by welding spatter, which reduces performance and service life, and existing solutions are inadequate for 'on-the-fly' processes, particularly due to insufficient spatter protection and gas atmosphere.
Innovation Solution
A splash-guard device with a pressure piece and spatter guard that generates targeted air flows to capture and remove welding spatter, using a combination of suction and blowing air, and incorporates angled tubes and after-flow openings to ensure comprehensive spatter capture and protection of the welding site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If air-blowing cleaning (cross jets) is used to protect against welding spatter, then the protective glass of the optics is protected, but particles are distributed or emitted in the system and adjacent welded joints are contaminated
Solution Approach 1:
The patent extracts the harmful welding spatter from the system by using a localized extraction system with suction nozzles positioned near the welding point, removing spatter before it can be distributed by air blowing or contaminate adjacent joints
Solution Approach 2:
The patent introduces a protective gas atmosphere as an intermediary between the welding point and the surrounding environment, preventing spatter from escaping while maintaining a controlled environment that doesn't distribute particles
2Object-generated harmful factors
If process extraction systems are used to capture welding spatter, then spatter removal is improved, but not all welding spatter is captured and the system is not suitable for on-the-fly laser welding
Solution Approach 1:
The patent makes the extraction system dynamic by positioning suction nozzles on the movable carriage that travels with the laser beam during on-the-fly welding, allowing continuous spatter capture throughout the welding process
Solution Approach 2:
The patent applies localized extraction with suction nozzles positioned very close to the welding point, creating a focused extraction zone that efficiently captures spatter at its source rather than using a general extraction system
3Area of stationary object
If protective gas is supplied from a considerable distance away, then the welding site is covered, but there is probably no protective gas left at the welding site itself
Solution Approach 1:
The patent supplies protective gas in advance through conduits that deliver gas close to the welding point before welding begins, ensuring the protective atmosphere is already in place when welding starts
Solution Approach 2:
The patent transitions from distant protective gas supply to localized supply by positioning gas outlets in close proximity to the welding point through strategically routed conduits, creating a concentrated protective atmosphere where needed
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 solution provides reliable spatter removal, preventing contamination and ensuring a dynamic, process-reliable laser welding process, enhancing battery cell performance and service life.
Implementation Method 1
an extraction system (26) for capturing and removing welding spatter; the second end (24) is designed as a connection for an extraction system (26)
Implementation Method 2
a pressure piece (14) for pressing onto the component to be welded; the pressure piece (14) has a pressure piece body (18) with a laser beam outlet mouth (20)
Implementation Method 3
a laser beam source (54) for directing a laser beam (58) onto the welding point (60.1, 60.2)
Data Source
AI summary
A splash-guard device for a laser welder for contact elements for electrical contacting. The deice has a pressure piece for pressing onto the component to be welded, and a spatter guard. The pressure piece has a pressure piece body with a laser beam outlet mouth, the edge of which surrounds the welding point when pressed on. The spatter guard is designed as an angled tube, the first end of which is sealed off from the pressure piece and the second end of which is designed as a connection for an extraction system. At least one laser beam entry opening is formed on an angled or curved region which is opposite the first end having the pressure piece. Also, a laser welder with such a splash-guard device.