Single-Position Sequential Laser Welding for Battery Terminal Tabs
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Solution Overview
Problem
The existing methods for laser welding battery cell terminal tabs to busbar terminal tabs require frequent re-aiming and repositioning of the welder, significantly slowing down the manufacturing process due to the need for multiple welding operations at different positions.
Innovation Solution
A single-position sequential laser welding system that aligns both positive and negative terminal tabs of a battery cell along a linear output path, allowing a laser to weld both tabs from a single position without changing its position or beam direction, and creates a fusible link by burning a hole through the connection to manage current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welder re-aims and repositions for each weld point, then welding precision is maintained, but manufacturing productivity decreases significantly
Solution Approach 1:
The patent segments the terminal tabs into two groups (first and second terminal tabs) that are spatially separated but collinearly arranged along the welding beam path. This allows the laser welder to maintain a fixed position while sequentially welding different segments, resolving the contradiction between maintaining precision through repositioning and improving productivity by avoiding repositioning.
Solution Approach 2:
The patent transitions from a traditional approach where the welder moves in multiple dimensions (re-aiming and repositioning) to a fixed-position approach where only the welding sequence changes. The terminal tabs are arranged along a one-dimensional linear path through the welding beam, eliminating the need for complex multi-dimensional welder movement while maintaining welding precision.
2Reliability
If multiple welding operations are performed at different positions, then complete welding coverage is achieved, but manufacturing time increases
Solution Approach 1:
The patent merges multiple welding operations into a single fixed-position process by arranging all terminal tabs along a collinear path through the welding beam. The welder performs sequential welding on different tab pairs without moving, combining what would traditionally require multiple repositioning operations into one continuous process, thereby reducing manufacturing time while maintaining complete welding coverage.
Solution Approach 2:
The terminal tabs are pre-positioned and arranged in a specific collinear configuration before the welding process begins. This preliminary arrangement ensures that all welding points are accessible from a single fixed welder position, eliminating the need for time-consuming repositioning operations during the welding process itself.
3Productivity
If terminal tabs are arranged in a linear path, then single-position welding is enabled, but manufacturing setup complexity increases
Solution Approach 1:
The patent employs an asymmetric arrangement where the first and second terminal tabs are positioned at different locations relative to the welding beam path, yet remain collinear. This asymmetric positioning allows single-position welding while maintaining proper electrical and mechanical connections, avoiding the need for symmetric arrangements that would require more complex welding setups.
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 number of welding operations, speeds up the manufacturing process, and provides an efficient method to prevent excessive current flow by creating a fusible link that can break if the current exceeds a certain rating, thereby protecting the electric power distribution system.
Implementation Method 1
activate an emission of a laser weld beam from a laser welder... toward a first terminal tab of a battery cell in contact with a first terminal tab of a busbar... welding the first terminal tab of the battery cell to the first terminal tab of the busbar
Implementation Method 2
The laser welder may be maintained in an emitting state such that the narrowed laser weld beam is directed through the hole and along the linear laser path in an emission direction toward a second terminal tab of the battery cell... welding the second terminal tab of the battery cell to the second terminal tab of the busbar
Implementation Method 3
narrow a focus of the laser weld beam changing the first beam diameter to a smaller second beam diameter... burning a hole through the welded first and second substrate inside the first weld area
Data Source
AI summary
Methods and systems for sequentially laser welding terminal tabs of a battery cell to corresponding terminal tabs of a busbar are described using a single laser position and path. The terminal tabs of a battery cell are aligned in contact with terminal tabs of a busbar. A laser welder, from a first position, generates a laser weld beam at a first diameter welding the first terminal tab of the battery cell to the first terminal tab of the busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without moving the laser welder from the first position, the narrowed laser weld beam burns a hole through the welded first set of terminal tabs, traverses a gap toward a second set of terminal tabs behind the first set and welds the second set together.