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In the production of electric vehicle batteries, battery cells are usually connected with conductive busbars to form modules. Depending on the energy storage requirements of the vehicle, multiple modules are often connected and assembled into a sealed enclosure or pack. A collection of these packs may be built into a tray structure or mechanically integrated into the vehicle chassis.
While there are many variations in the size and style of electric battery packs and trays, the welding requirements of this application are consistent. Aluminum, which is present in growing volumes in newer electric vehicles and is the metal of choice for pack enclosures and structural tray assemblies, is notoriously challenging to weld. The aluminum weld seams that join pack walls and packs to trays must be structurally sound and free of cracking or porosity to withstand the shock forces of vehicle use and packs in particular must be hermetically sealed to avoid damaging the battery cells inside.
Creating high quality battery pack and tray weld seams is just one manufacturing challenge. Battery manufacturers, who produce many thousands of batteries each year, must also produce these high quality welds quickly and repeatably. Fiber laser welding, a method that has been widely adopted by leading E-Mobility manufacturers, both creates strong aluminum welds free of cracks and porosity and is faster, more reliable, and more easily automated than other welding methods.
Contact an E-Mobility expert to learn more about how IPG laser solutions can optimize your battery pack and tray production.
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1. High-Speed Welding Increases Throughput
The unmatched capabilities of IPG lasers enable high-speed battery pack and tray welding that creates high-strength joints faster and more reliably than any other laser welding solutions on the market.
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2. Weld Porosity Virtually Eliminated
Weld porosity, which can compromise the strength of battery pack and tray joints, is virtually eliminated by dual-beam technology that allows high welding speeds without compromising weld results.
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3. Excellent Joint Quality and Part Gap Bridging
Wobble welding technology enables the creation of strong, defect-free welds with precise control of final joint dimensions and the flexibility to bridge variable gaps between battery pack enclosure walls.
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4. Real-Time Weld Measurement for 100% Quality Assurance
IPG patented weld measurement technology provides highly accurate, non-destructive weld measurements on each weld as it is performed for 100% weld quality assurance with no additional cycle time.
IPG partners with E-Mobility manufacturers throughout the entire production process from research and development to full-scale manufacturing.
Whether you want to demonstrate feasibility with laser-processed parts or just want to bounce design and implementation ideas off an experienced laser application engineer, don’t hesitate to contact us. Even better, visit one of our 25 regional Application Development Labs to see how IPG can optimize your battery pack and tray production.
