SHINHOP laser

Laser welding technology effectively improves the intelligent manufacturing level of power batteries. New energy vehicles have developed rapidly in recent years, and the supporting power batteries represent another new large market with broad development prospects. As a new type of clean energy, power batteries can provide good driving force for various means of transportation, becoming not only the power storage device for new energy vehicles, electric bicycles, electric trains, and even electric airplanes and submarines.

Laser welding processing is widely used in the battery production and manufacturing field. Currently, only lasers can better achieve the quality process of battery welding because there are many parts of the battery that need to be welded, and the difficulty is high. It is important to note that new energy vehicles have strict requirements for the cost, safety, and environmental control of power batteries, and general welding can reach its process level.

Compared to traditional welding, laser welding has a better non-contact welding method, high flexibility, and can achieve multi-directional and multi-angle automated welding. More importantly, its welding precision is high, and the quality level of the process meets the technical requirements of new energy power batteries, which is an important guarantee for the technology and application of power batteries.
What parts of the power battery need laser welding? Currently, the main ones include explosion-proof valve welding, battery tab welding or aluminum to nickel transition, battery tab spot welding, sealing welding of the power battery shell and cover plate, and welding of power battery modules and PACK.
1. Explosion-proof Valve Welding
The explosion-proof valve is a thin-walled valve body on the battery sealing plate. The structure of the explosion-proof valve is ingenious, and many are patented designs by battery manufacturers. However, its basic principle is to use laser welding to firmly bond two aluminum metal sheets of a certain shape. When the internal pressure rises to a certain value, the aluminum sheet breaks at the designed groove position to prevent further expansion of the battery from causing an explosion. This process has extremely strict requirements for the laser welding process, requiring the weld seam to be sealed, and the failure pressure of the weld seam must be greater than the failure pressure at the aluminum sheet groove position. Continuous laser welding can achieve high-speed, high-quality welding, ensuring stability, efficiency, and yield.


Currently, the common laser welding solutions on the market are:
Welding Method: Continuous Welding
Recommended Model: 1000W Continuous
Alignment Precision: <0.05mm
Fiber Core Diameter: 50um
Welding Power: 800～900W
Welding Speed: 70～90mm/s
2. Pole Welding
Power batteries generally have positive and negative pole columns for current output and connection to external circuits. To meet the high capacity usage requirements, power batteries generally need to be connected in series or parallel using connecting plates. When the batteries are grouped, the connection between the positive and negative pole columns and the connecting plates is generally done by welding.

Currently, the common laser welding solutions on the market are:
Welding Method: Continuous Welding
Recommended Model: 1000W Continuous
Alignment Precision: <0.05mm
Fiber Core Diameter: 50um
Welding Power: 700～900W
Welding Speed: 50～60mm/s
3. Soft Connection Welding
The soft connection of new energy power battery vehicles refers to the connecting wires between the electric vehicle battery packs, which can be bent and are called soft connections. The materials are mainly copper and aluminum, and after welding treatment, they do not produce acid leakage and have better conductivity.

Currently, the common laser welding solutions on the market are:
Welding Method: Continuous Welding
Recommended Model: 6000W Continuous
Alignment Precision: <0.05mm
Fiber Core Diameter: 150um
Welding Power: Aluminum 2000～3000W, Copper 3900～4500W
Welding Speed: 110～130mm/s
4. Shell Sealing Welding
The shell materials of power batteries are aluminum alloy and stainless steel, with aluminum alloy being the most commonly used, generally 3003 aluminum alloy, and a few using pure aluminum. The welding forms of the shell are divided into top welding and side welding. Using continuous laser welding for thin-shell power batteries can increase efficiency by 5 to 10 times, and the appearance and sealing performance are better. Currently, the common laser welding solutions on the market are:


Welding Method: Continuous Welding
Recommended Model: 2000W Continuous
Alignment Precision: Gap <0.05mm, Height 0.06
Fiber Core Diameter: 100um
Welding Power: 1100～1300W
Welding Speed: 50～70mm/s
5. Liquid Injection Hole Welding
In the manufacturing process of lithium batteries, when injecting electrolyte into the battery shell, it is necessary to seal the liquid injection port of the battery shell to maintain the stability of the electrolyte. Currently, laser welding sealing is commonly used, which has high efficiency and good sealing effect.
Currently, the common laser welding solutions on the market are:

Welding Method: Continuous Welding
Recommended Model: 1000W Continuous
Alignment Precision: Gap <0.05mm, Height 0.06
Fiber Core Diameter: 100um
Welding Power: 750～950W
Welding Speed: 40～70mm/s
6. PACK Welding
The process of assembling battery cells into groups is called PACK, which can be a single battery or a series-parallel battery module, etc. The advantage of laser welding is good reliability. The positive and negative pole materials are different, generally copper and aluminum. Since both copper and aluminum have fast heat transfer and very high reflectivity to lasers, and the thickness of the connecting piece is relatively large, a higher power laser is required to achieve welding.

Currently, the common laser welding solutions on the market are:
Welding Method: Continuous Welding
Recommended Model: 3000W/6000W Continuous
Alignment accuracy splicing gap <0.1mm height gap <0.05
Optical fiber core diameter 100um/150um/200um
Welding power splicing welding: 2000W～3000W T≤2mm overlay welding: 3000W-5000W T≥1.5mm
Welding speed 60～80mm/s
7. In addition to welding applications, laser cutting technology can also be applied in the field of power batteries.
1. Ear laser cutting:
Ear cutting is a key process in power batteries. Currently, common cutting methods include die-cutting technology and laser cutting technology. Compared with traditional die-cutting, ear laser cutting, as a new process, has characteristics such as no consumables, fast speed, high flexibility, and strong adaptability, which can reduce manufacturing costs, improve production efficiency, and significantly shorten the die-cutting cycle for new products, while being applicable to different types and specifications of products.
Before ear cutting                                After ear cutting

Materials aluminum, copper foil
Cutting method online galvanometer cutting
Cutting speed ≥60m/min
Edge burr height ≤7 μm
Heat affected zone ≤50 μm
Recommended laser 100W/200W MOPA
Power batteries, as core components of new energy vehicles, directly determine the performance of the entire vehicle. With the gradual explosion of the new energy vehicle market, fiber lasers will have great market potential in the future.