402030 battery

Introduction to laser welding of 402030 battery module CCS components

Power batteries are composed of countless single cells combined according to certain quantities and requirements to form a complete battery pack, so the single cell is the smallest unit of the power battery. So how is the battery pack composed of cells? Specifically, several battery cells are assembled and welded together in parallel to form a battery module, which is a PACK module; several battery modules are connected in series to form a battery unit;

The on-board power supply usually exceeds 300 volts and 200A. The basic method now is to connect single cells in parallel to form a module, connect module batteries in series to form a battery pack, and connect battery packs in series to form a power system.

PACK refers to the battery pack of new energy vehicles, which provides "energy" for the operation of the entire vehicle. We can briefly understand what systems the power battery PACK assembly consists of and what parts each system consists of? In order to let everyone understand the battery PACK more intuitively, take the PACK of the Audi A3 Sportback-etron hybrid vehicle as an example. Generally speaking, the power battery PACK of electric vehicles consists of the following parts: power battery module system, structural system, thermal management system, BMS. If the battery PACK is compared to a human body, then the module is the "heart", which is responsible for storing and releasing energy to provide power for the car. PACK mainly refers to the processing, assembly and packaging of battery packs. It can be a single battery or a PACK of a 402030 battery pack in series and parallel, including battery packs, busbars, soft connections, protective board outer packaging, plastic brackets and other auxiliary materials. These items together constitute PACK. The system uses mechanical structure to connect many single cells in series and parallel, and considers mechanical strength thermal management, BMS matching and other issues. Its main technology is reflected in the overall structure, design, welding and processing technology control protection level, active thermal management system, etc.

And CCS is an indispensable part in the battery pack process.

CCS (Cells Contact System, integrated busbar, wiring board integrated components) products are composed of FPC, plastic structural parts, copper and aluminum busbars, etc. New energy vehicle power batteries are generally composed of multiple battery modules. A single battery module corresponds to 1 CCS. 1 CCS is generally equipped with 1-2 FPCs. CCS integrates plastic structural parts, copper and aluminum busbars and other structural parts. In the field of power battery applications, FPC is mainly used to replace traditional wiring harnesses in the pack link to assist in the information collection of battery packs.

Power battery module FPC During welding, the welding materials involve nickel and copper-plated nickel, mainly nickel-aluminum welding. During welding, it is easy to have cold welding, welding penetration, explosion points, welding deviation and other phenomena, which are specifically manifested as follows:

Different melting points of dissimilar metals: When the low-melting-point material melts, the high-melting-point material is still in a solid state. At this time, the melted material is easy to penetrate into the grain boundary of the overheating zone, causing the loss of low-melting-point materials, burning and evaporation of alloy elements, and changes in the chemical composition of the weld, making it difficult to control the mechanical properties;

Different linear expansion coefficients of dissimilar metals: Different linear expansion coefficients of dissimilar metals lead to large welding stress and welding deformation during the crystallization of the molten pool. Due to the different stress states on both sides of the weld, it is easy to cause cracks in the weld and heat-affected zone, and even cause the weld metal to peel off from the parent material;

Different thermal conductivity and specific heat capacity of the materials: The crystallization conditions of the weld metal deteriorate, the grains are coarse, and the wetting properties of the refractory metal are affected;

Dissimilar metal welding is prone to produce intermetallic compounds, and at the same time, changes in the organization occur, resulting in a decrease in the mechanical properties of the weld joint, especially cracks in the heat-affected zone.

In addition, the thermal properties of the material, such as the linear expansion coefficient, thermal conductivity and specific heat capacity, change with temperature, making the laser welding process of dissimilar metal materials more complicated.

Therefore, in addition to solving the series of problems of dissimilar metal welding, the high-quality power battery FPC welding process must also avoid problems such as false welding, welding penetration, explosion points, and welding deviation while improving the automation, intelligence and efficiency of FPC welding.

In response to the laser welding needs of CCS components, laser equipment manufacturers have launched corresponding laser welding equipment, which has good welding performance and welding quality, and has been well received by end customers through actual use.

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