Sinusoidal Laser Welding for Battery Module Copper Joints
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Solution Overview
Problem
Traditional welding methods for battery modules are costly and can damage electronics or the housing due to energy transfer, and are imprecise, especially when dealing with copper components, which are difficult to weld effectively due to their reflective and conductive nature.
Innovation Solution
A laser welding system that uses a high-power laser with a small spot size and oscillating pattern to create a sinusoidal lap weld between copper components, allowing for precise and strong connections without additional welding materials, and minimizing heat transfer to sensitive electronics and housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to join battery module components, then strong connections can be achieved, but significant heat is transferred to surrounding electronics and housings causing damage
Solution Approach 1:
The patent applies local quality by concentrating laser energy into a focused beam with small spot size, creating a localized weld zone with intense energy density that melts and fuses components together while the surrounding areas remain relatively cool due to the precision of energy localization
Solution Approach 2:
The patent replaces traditional mechanical or thermal welding systems with a laser-based welding system. The laser beam provides non-contact, precise energy delivery that eliminates the need for physical contact tools and reduces overall heat transfer to surrounding components compared to conventional welding methods
2Manufacturing precision
If high-power laser with small spot size is used to weld copper components, then precise and strong welds are achieved, but the reflective and conductive nature of copper makes welding difficult
Solution Approach 1:
The patent employs periodic action by using pulsed laser welding instead of continuous laser welding. The pulsed delivery allows the copper material to heat up and reach melting point during the pulse duration, then cool slightly between pulses, preventing excessive heat loss and enabling cumulative heating effect that overcomes copper's high thermal conductivity
Solution Approach 2:
The patent applies parameter changes by adjusting laser welding parameters including pulse duration, power density, spot size, and welding speed to optimize the welding process for copper's specific properties. These parameter adjustments enable effective welding despite copper's reflective and conductive characteristics
3Ease of manufacture
If conventional welding processes are used for battery modules, then welding can be performed, but the process is costly and damages housing and electronics
Solution Approach 1:
The patent replaces conventional mechanical welding systems with a laser welding system that provides non-contact energy delivery. This substitution eliminates the need for physical contact between welding tools and workpiece, reducing mechanical stress and heat transfer to surrounding components while maintaining welding capability
Solution Approach 2:
The patent introduces the laser beam as an intermediary that transfers energy from the power source to the workpiece without physical contact. This intermediary enables precise energy delivery to the weld zone while isolating the heat source from surrounding electronics and housing, preventing damage
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 laser welding system produces strong, clean, and uniform welds with higher tensile strength and reduced heat penetration, enabling efficient and precise attachment of copper components in battery modules while protecting surrounding electronics and housings.
Implementation Method 1
A laser welding system that uses a high-power laser with a small spot size and oscillating pattern to create a sinusoidal lap weld between copper components
Implementation Method 2
A laser welding system that uses a high-power laser with a small spot size and oscillating pattern to create a sinusoidal lap weld
Data Source
AI summary
The present disclosure relates generally to a welding process for a battery module. In an embodiment, a system for welding two components in a battery module includes a laser source configured to emit a laser beam onto a workpiece having a first battery module component and a second battery module component. The system also has an actuator coupled to the laser source and configured to move the laser beam along a first axis and a second axis and a controller electrically coupled to the laser source and the actuator. The controller is configured to send a signal to the laser source and the actuator to form a sinusoidal lap weld on a surface of the workpiece, such that the first battery module component is electrically coupled to the second battery module component.