Laser Welding in EV battery market

Growing EV battery market demands better joining solutions: Wobble laser Welding is the best

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Laser Beam Welded Joints for Lithium-Ion Batteries

The rapid growth in electrification for vehicles and tools is driving the need for highly efficient joining solutions. Modern electric vehicle (EV) batteries are made up of numerous individual battery cells that work together to achieve optimal nominal voltage and energy output. Each battery cell requires a reliable connection at its terminals, leading to an increased necessity for automated joining processes that ensure minimal joint resistance. This is essential to mitigate energy loss across cell connections, thus enhancing overall efficiency. Laser beam welding has emerged as an effective technique, well-suited for joining conductive materials such as copper and aluminum in these applications.

As the demand for extensive battery packs in EVs continues to rise—fueled by both advances in transportation electrification and consumer demands for better vehicle ranges—the quality of connectivity among the battery cells stands paramount. For instance, the Tesla Model S features around 18,650 battery cells in its pack. A malfunction or defect in any single connection can dramatically hinder battery performance. The performance and longevity of these vehicles are closely linked to the integrity of welded connections: increased resistance at a weld point can produce excess heat and impose higher electrical and thermal loads on individual battery cells, potentially culminating in failures or accelerated aging.

Laser beam welding presents a compelling solution by facilitating the precise, fast, and automated creation of highly conductive joints between battery cells. In contrast to traditional welding methods like resistance spot welding, laser beam welding minimizes thermal energy input. Moreover, unlike ultrasonic welding, it avoids introducing mechanical forces that could compromise the joint integrity. This results in transition resistances that are on par with the fundamental material resistances. Consequently, the overall performance of the battery packs improves, characterized by reduced ohmic resistance in the joints and diminished heat loss during operation.

The conductivity of the welds joining battery cells is crucial, as high currents must traverse these connections to power electric vehicles. These joints often represent the weak link in the power circuit; electrical resistance at the weld can elevate temperatures, which may adversely affect lithium-ion cells. With our wobble laser system, we can produce larger weld areas, which in turn reduces resistance. The welds created by this system significantly enhance mechanical strength and lower thermal stress at the junctions, making Wobble Laser Welding a more advantageous technique for assembling battery tabs than conventional methods.

Moreover, laser beam welding minimizes the heat-affected zone, which is vital in preventing any heat damage to the battery components. Lithium-ion batteries have strict operational parameters defined by temperature and voltage limits. Exceeding these thresholds can lead to swift degradation of battery functionality and may pose safety hazards.

When it comes to production, laser beam welding is exceptionally suited for integration into largely automated assembly lines within battery pack production and EV manufacturing.

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