Abstract
The qualification of production systems that enable reliable and stable production processes is a major challenge in manufacturing large-format lithium-ion batteries. During cell assembly, the electrode sheets of the anode and the cathode are stacked, and are electrically contacted by a welding process. It was shown that laser beam welding employing a beam source in the green wavelength range is a promising joining approach in terms of high productivity. Therefore, the influence of the process parameters, such as the laser power, the welding speed, the pulse frequency, and the pulse duration, on the weld seam quality was investigated. Particular emphasis was placed on the mechanical strength of the weld seam. Statistically planned experiments were used to determine feasible parameter sets for welding the most common current collectors of lithium-ion battery electrodes, copper (Cu), and aluminum (Al). The influence of the individual process parameters on the tensile shear force was evaluated. Stacks of 40 metal foils were welded with a thin metal sheet in lap joint configuration. Based on an analysis of the requirements for minimum mechanical seam strengths, this study confirms that laser beam welding using a green high-power disk source is an auspicious process for the internal contacting of lithium-ion batteries.
Highlights
As a result of the transition to renewable energies, the demand for electrical energy storage systems is continuously increasing
lithium-ion batteries (LIBs) are made of multiple electrochemical elementary cells composed of an anode and a cathode, which are electrically isolated by a separator layer [3]
To account for industrially relevant processing times, the minimum welding speed was set to mm clamping lever welding recess clamping bridge z x y base plate positioning test plate specimen foil stack
Summary
As a result of the transition to renewable energies, the demand for electrical energy storage systems is continuously increasing. Due to their high energy and power densities, lithium-ion batteries (LIBs) are used in many applications, e.g., portable electronics, power tools, and electric vehicles (EVs) [1], as preferential battery technology [2]. LIBs are made of multiple electrochemical elementary cells composed of an anode and a cathode, which are electrically isolated by a separator layer [3]. The process chain for manufacturing LIBs consists of a large number of process steps. Electrochemically active materials are mixed with conductive additives as well as binding agents [4] The cells are filled with liquid electrolyte and the layers
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