Mar. 31, 2025
Machinery
As the demand for high-performance, long-lasting batteries continues to rise, ensuring the quality and reliability of the battery assembly process has become critical. Laser welding is one of the cutting-edge technologies that has contributed significantly to the advancement of battery technology. This article will take you inside the world of laser welding for lithium batteries, providing a comprehensive overview of the unique capabilities and applications of this precision welding technology.
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Laser welding technology is an advanced processing technology for the production of high-performance power batteries. Since power batteries need to have multiple welding parts and it is difficult to carry out high-precision requirements met by traditional welding methods, laser welding technology can weld welds with high quality and automation due to the characteristics of small welding consumables loss, small deformation, strong stability and easy operation. Applied to the welding e-mobility battery, it can greatly improve the safety, reliability and service life of the battery.
Ultrasonic welding utilizes mechanical vibrations generated by high-frequency vibrations (usually above 20 kHz) to heat the welded joints, melting and joining the materials together. In lithium battery production, ultrasonic welding is commonly used to connect battery cells to electrode foils, electrode cells to electrolyte films, and battery cells to battery casings and other components. It provides a highly accurate and stable weld, avoiding thermal damage and the introduction of impurities.
Laser welding uses a laser beam to heat the weld joints to a high temperature, causing the materials to melt and join together. Laser welding offers high energy density and joint precision. Laser welding is commonly used to join components such as electrode foils, battery casings, and battery connecting tabs. It provides non-contact, high precision and high speed welding for a wide range of different materials and complex geometries.
Resistance welding is a welding method that heats and joins two materials by generating heat through the material with an electric current. Resistance welding is commonly used to weld components such as battery cells to electrode foils and battery cells to connecting tabs. It is a common welding method, but requires proper control to avoid overheating and thermal damage.
TIG welding uses the high temperatures generated by the arc to melt the weld material, while an inert gas (usually argon) is used to protect the weld area from oxidation. TIG welding is commonly used to join components such as battery cases, battery covers, and battery leads.
Laser welding lithium ion batteries is a highly advanced and efficient welding method. It not only improves production efficiency but also ensures product quality and stability.
1. Efficiency: Compared to traditional welding methods, laser welding of lithium-ion batteries offers higher efficiency. This is because laser welding can complete a large amount of work in a short time without the need for any auxiliary materials.
2. High Precision: Laser welding of lithium-ion batteries can achieve very high precision. This is because the laser beam can focus precisely on the weld seam, ensuring the quality and stability of the welding.
3. Environmentally Friendly: Laser welding of lithium-ion batteries does not produce any harmful substances, making it very environmentally friendly. Additionally, as it does not require the use of solvents or other chemicals, it can also reduce waste production.
4. High Welding Quality: Lithium-ion battery laser welding equipment uses a non-contact welding method, which means there is no mechanical contact, thus avoiding the possibility of material damage after welding. Furthermore, the laser beam locally heats the welding area, allowing the welding area to quickly reach a high temperature, followed by rapid cooling, resulting in rapid solidification of the welding area, creating strong and aesthetically pleasing weld seams.
5. Wide Applicability: Laser welding of lithium-ion batteries can be applied to various types of lithium-ion batteries, including lithium-ion, polymer lithium-ion, and NMC lithium-ion batteries. Additionally, it can also be applied to various materials, such as aluminum, copper, stainless steel, etc.
By using laser welding, it is possible to efficiently and precisely weld critical components such as battery protection boards, tab connections, battery cover plates, series connectors, terminals, and more during the production process. Compared to traditional methods like brazing and resistance welding, laser welding technology can reduce material costs, increase production efficiency, and enhance the quality of weld seams.
1. In EV: With the increasing popularity of electric vehicles, there is a growing demand for high-performance and high-safety batteries. Replacing traditional welding techniques with laser welding in the production of power battery modules for electric vehicles not only significantly increases production speed but also improves the qualification rate of lithium battery pack modules and the safety of the travel safety.
2. in the energy storage industry: storage systems are a crucial focus in the future of energy development. Laser welding for storage batteries can offer a more reliable and secure battery connection solution for energy storage systems.
3. Liquid cooling plates: The performance of liquid cooling plates can impact the performance of power batteries. As the structure of liquid cooling plates becomes more diverse, the requirements for welding processes are increasingly demanding. Laser welding, with its high-precision welding control, can achieve micron-level accuracy, which is crucial for manufacturing complex geometries and structures of battery liquid cooling plates. Laser welding of water cooling plates can improve welding efficiency, increase welding productivity, reduce welding costs, and enhance welding quality and stability.
4. in the electronics industry: As people rely more on portable electronic devices, the demand for high-performance and high-capacity batteries continues to grow. Laser welding machine for lithium batteries can provide more stable and efficient battery solutions for electronic products.
Laser welding system for lithium-ion batteries is widely used in various stages of the battery production process, including the welding and connecting of components such as tabs, cells, series connectors, protection plates, and terminals. Thanks to its efficiency and precision, laser welding equipment has become an essential tool for lithium battery manufacturers.
During the assembly and welding of lithium battery pack, a significant amount of nickel-plated copper or nickel-plated aluminum is used to connect battery cells. The primary method of connection is nickel-aluminum welding. However, aluminum alloys have high reflectivity and are sensitive to the formation of pores, leading to issues like porosity, thermal cracks, and ruptures during the welding process. The design and welding quality of the automatic laser welding machine will affects the cost, quality and safety of lithium battery packs.
DPLASER, many years of experience in industrial laser equipment production, has developed an automatic laser welding machine designed for battery module manufacturing. This lithium battery laser welding machine utilizes laser technology to complete the welding process and can be equipped with visual positioning software for precise alignment and a multi-axis linkage system. The equipment is characterized by high efficiency, minimal consumables, aesthetically pleasing weld seams, strong weld joints, and user-friendly operation. It can be seamlessly integrated into automated production lines, enhancing the production capacity and efficiency of lithium battery pack assembly lines, meeting the battery welding needs of various industries. Additionally, we also offer customized robotic laser welding solutions for welding battery terminals, casings, and cover plates ensuring seal welding.
E-Mobility battery laser welding machine can weld battery tabs, terminals and lithium battery modules and cases.
1. Outstanding performance ensures a consistently strong and reliable welding effect, delivering top-notch results every time.
2. This welding system maintains a high level of stability during operation, utilizing a fully-automatic welding method that streamlines the process and saving labor
3. Its compact size makes it effortlessly integration with production lines, facilitating a smooth and efficient assembly process.
4. With remarkably low energy consumption, this welder is virtually maintenance-free, saving you both time and money in the long run.
5. Engineered for longevity, this welding equipment is exceptionally durable and boasts an extended service life, offering sustained value over time.
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6. Its exceptional efficiency allows for rapid and precise welding, boosting productivity and reducing production time.
7. In addition to its impressive performance and features, this welding solution proves to be a cost-effective choice, making it an attractive option for businesses looking to optimize their welding processes without breaking the bank.
The applications of laser technology in the new energy industry, especially in the manufacture of battery packs and lithium battery, has been gradually expanding to include equipment such as battery laser welding machines and laser marking machines. Laser marking machines have a variety of applications in lithium battery manufacturing, and they help mark, track, identify and manage battery packs, improving quality control, production efficiency and product traceability.
Battery Component Marking: Laser marking machines can be used to mark battery components, such as battery cells, battery lugs, battery terminals, battery casings, etc., to ensure that they can be tracked and identified. This marking can include information such as product model, date of manufacture, company logo, barcode or QR code.
Manufacturing date and lot traceability: Laser marking machines can be used to mark manufacturing date and lot information on battery components for traceability and quality control when required.
Tracking and Management: The marking information from the laser marking machine can be used to build a database of information about the battery assembly to track the performance, history and usage of each cell. This is very helpful in the management and maintenance of battery components.
Customized marking: Battery manufacturers can use laser marking machines to mark battery components with customized information according to customer requirements, such as customer logos, special specifications or serial numbers.
Using laser marking machines for lithium battery manufacturing helps to improve product quality, traceability and management efficiency. They provide high-precision, non-contact and efficient automated marking solutions for a wide range of battery pack sizes and shapes.
Finally:
Laser welding finds extensive and dynamic applications in the lithium-ion battery industry, enabling precise and efficient connections in the complex field of battery assembly. From ev battery to batteries for electronic devices, lithium battery laser welding machine is broad and far-reaching. Whether you are a manufacturer in battery manufacturing or simply curious about innovative technologies driving the development of the battery industry, we are eager to explore the various possibilities that laser welding brings to the world of lithium-ion batteries with you.
Whether prismatic cells or cylindrical cells, welding is one of the important processes in battery production. In the lithium battery production line, the production section of the welding process is mainly concentrated in the cells assembly and PACK line section, see the figure below:
Brief description of welding process details
1. Safety vent welding
The safety vent, also known as the pressure relief valve, is a thin-walled valve body on the top cover of the battery. When the internal pressure of the battery exceeds the specified value, the safety vent ruptures and releases the pressure to prevent the battery from bursting. The safety vent has an ingenious structure. It usually uses laser welding to fix two aluminum metal sheets of a certain shape. When the internal pressure of the battery rises to a certain value, the aluminum sheet breaks from the designed groove position to prevent the battery from further expansion and explosion. Therefore, this process has extremely strict requirements on laser welding technology. The weld seam is required to be sealed and the heat input is strictly controlled to ensure that the damage pressure value of the weld seam is stable within a certain range (generally 0.4~0.7MPa). Too large or too small will have a great impact on the safety of the battery.
2. Terminal welding
The terminals on the battery cover plate are divided into positive and negative terminals. The function of the terminals is also divided into internal and external connections. The internal connection is the welding of the battery tabs to the terminals. The external connection is the welding of the battery terminals through the connecting strips to form series and parallel circuits to form a battery pack.
The battery terminals generally use aluminum for the positive electrode and copper for the negative electrode, and usually use a riveted structure. After the riveting is completed, welding is performed, usually a circle with a diameter of 8mm. When welding, as long as the tensile force and conductive properties of the design requirements are met, fiber lasers or hybrid welding lasers with good beam quality and uniform energy distribution are preferred. Use fiber laser or hybrid welding laser for welding. It can realize the stability of aluminum-aluminum structure welding and copper-copper structure welding of electrical terminals, reduce spatter, and thereby improve the welding yield.
3. Tab extension welding
The tab extension sheet is a key component that connects the battery cover and the battery jelly roll. It must also take into account the overcurrent, strength and low spatter requirements of the battery. Therefore, during the welding process with the cover, there needs to be sufficient weld width, and it is necessary to ensure that no particles fall on the battery jelly roll to avoid battery short circuit. Copper, as the negative electrode material, is a high-reflective material with low absorption rate and requires higher energy density during welding.
4. Cans sealing welding
The casing materials of power batteries include aluminum alloy and stainless steel. Among them, aluminum alloy is used most, and a few use pure aluminum. Stainless steel is the material with the best laser weldability, especially 304 stainless steel. Whether using pulse or continuous laser, welds with good appearance and performance can be obtained. Using continuous laser to weld thin-shell lithium batteries can increase the efficiency by 5 to 10 times, and the appearance and sealing properties are better. Now, in order to pursue faster welding speed and more uniform appearance, most companies have begun to use hybrid welding and annular light spot to replace the previous low-speed single fiber welding. At present, the welding speed of most companies' mass production lines has reached 200mm/s. For the low-speed fiber optic welding lines of some manufacturers, in order to ensure the stability of the weld bead, the general mass production speed is 70mm/s.
5. Sealing nail welding
Sealing nails (filling hole caps) also come in many forms, and their shape is usually a round cap with a diameter of 8mm and a thickness of about 0.9mm. The basic requirement for welding is that the withstand pressure value reaches 1.1MPa, and there should be no pinholes, cracks or explosion points. As the last process of battery cells welding, the yield of sealing nail welding is particularly important. Due to the presence of residual electrolyte during welding of sealing nails, defects such as explosion points and pinholes will occur. The key way to suppress these defects is to reduce the heat input. The use of laser welding can greatly improve stability and compatibility, thus greatly improving the yield rate.
6. PACK Busbar welding
The battery module can be understood as a combination of lithium-ion cells connected in series and parallel, with a single battery monitoring and management device installed. The structural design of the battery module often determines the performance and safety of a battery pack. Its structure must support, fix and protect the battery cells. At the same time, how to meet overcurrent requirements, current uniformity, how to control the cell temperature, and whether the power can be cut off in case of serious abnormalities to avoid chain reactions, etc., will all be the criteria for judging the quality of battery modules. Since laser welding between copper and aluminum tends to form brittle compounds that cannot meet the usage requirements, ultrasonic welding is usually used. In addition, copper and copper, aluminum and aluminum are generally laser welded. At the same time, because both copper and aluminum conduct heat very quickly and have very high laser reflectivity, and the thickness of the tab extension sheet is relatively large, a higher-power laser is required to achieve welding.
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