Laser Processing on Power Batteries Application Note

The demand for power batteries is growing fast with the rapid development of new energy vehicles. The shape of the electric battery cells is divided into cylindrical, soft pack, and square cells. The shell material is mainly made of aluminium and stainless steel, of which rectangular and aluminium are the primary materials.

Laser Processing on Power Batteries 1
Figure 1. The Electric Battery Cells

Operation Principle & Application

1. Laser Cutting on the Pole Ear

There are four types of battery materials:

1) NiMH Batteries

2) Fuel Battery

3) Lead-Acid Batteries

4) Lithium Electronic Batteries.

The production of lithium batteries is a “roll-to-roll” process, whether it is lithium iron phosphate, sodium ion, or ternary batteries, all of them need to go through the process from thin film to individual battery, and then be mounted into a battery system. The lithium battery production process includes electrode production, battery cell assembly, and packaging.

Lithium batteries are mainly composed of positive electrodes, negative electrodes, diaphragms, electrolytes, and battery casings. A laser is used to cut and form positive and negative electrodes.

Laser Processing on Power Batteries 3
Figure 2. Pole Ear Slitting
Laser Processing on Power Batteries 5
Figure 3. Pole Ear Cutting and Forming
Laser Used1064nm MOPA 250W
Beam Expander1.5x or 2x
Scanner Aperture14mm
Scan LensF120 and F160
Scan Area50x50mm
Table 1. Diagram Specifications
Part NumbersWavelengthFLScan AreaApertureWDSpot Size
TSL-1064-70-163Q-D141064nm163mm70x70mm14mm224mm22.3-22.6um
TSL-1064-60-160Q-D141064nm163mm60x60mm14mm164mm22.6-23.4um
TSL-1064-52-120Q-D141064nm120mm52x52mm14mm166.8mm17.3-19.6um
TSL-1064-35-110Q-D141064nm110mm35x35mm14mm145mm15.3-16.0um
Table 2. Scan Lens for Laser Cutting Pole Ear of Power Battery

2. Laser Cleaning on Foil

The positive and negative electrodes of lithium batteries are made by coating with aluminum and copper foil, The foil needs to be cleaned before coating to obtain a completely clean and oxide-free surface.

Part NumbersWavelengthEFLScan FieldApertureWDSpot Size
TSL-1064-85-167Q-D201064nm167mm85×85mm20mm226.3mm16.0-36.0μm
SL-1064-215-340Q-D151064nm340mm215×215mm15mm204.8mm43.8-49.7μm
SL-1064-175-254Q-D101064nm254mm175×175mm10mm304.0mm51.6-55.3μm
SL-1064-170-255Q-D201064nm255mm170×170mm20mm319.4mm29.4-50.8μm
Table 3. Scan Lens for Laser Cleaning on Power Battery

3. Laser Welding on Power Battery

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Figure 4. Scan Welding System

The laser welding process on power batteries includes welding, leak detection, short circuit detection, and coding and marking. Different Pulsed lasers will be used for welding according to battery material, thickness, and shape.

Scan welding system consists of a collimator, scanner, scan lens, objective lens, CCD, dichroic mirror, connecting plate and air knife, etc.

Collimator P/NWavelengthEFLNA
COL-1064-D30-F75Q-0.12-WC-V21064nm75mm0.12
COL-1064-D30-F100-0.1-WC-V21064nm100mm0.1
COL-1064-D30-F125-0.1-WC-V21064nm125mm0.1
COL-1064-D46-F150Q-0.1-WC-V21064nm150mm0.1
COL-1064-D40-F120-0.125-WC-HP31064nm120mm0.125
COL-1064-D40-F140-0.11-WC-HP31064nm140mm0.11
Table 4. Collimator for Scan Welding System
Scan lens P/NFLScan AreaApertureWDSpot Size
SL-1064-120-254Q-D30-WC254mm120X120mm30mm311.6mm16.6-59.4um
SL-1064-180-348Q-D30-WC348mm180X180mm30mm438.0mm25.4-64.4um
SL-1064-180-400Q-D30-WC400mm180X180mm30mm504.5mm25.9-27.4um
SL-1064-250-500Q-D30-WC500mm250X250mm30mm608.5mm33.4-54.6um
Table 5. Scan Lens 2kw-6kw Scan Welding System

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