E-Mobility Manufacturing Solutions
Manufacturers of electric vehicles and the battery sources that enable them come to IPG for laser-based manufacturing solutions. Covering the range of battery production steps from processing of electrode films through welding the structural components of the battery trays, IPG’s technical leadership in the area of laser-material interactions allows us to provide industry-leading guidance and support to automotive manufacturers and their chosen production line integrators.
Whether it is the unmatched power levels of pulsed foil cutting lasers, the unique capabilities of the adjustable mode beam lasers for spatter-free welding of copper and aluminum, or patented real-time weld measurement technology, IPG is continually working to optimize laser materials processing capabilities to keep you ahead of rapidly evolving e-mobility trends.
Li-ion Cell Manufacturing
Despite the differences between cylindrical, prismatic or pouch designs, cell manufacturing typically relies on laser processing for the cutting and notching of foils, welding of the foil stacks to tabs, cell case injection hole sealing, safety valve welding, and cap-to-case sealing. Together with emerging technologies such as laser drying of the electrode coating, these processes consistently deliver the high speed and high yield required for high-volume Li-ion cell production.
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Busbar Welding
For all battery cell technologies, whether cylindrical, prismatic or pouch, conductive busbars are used to connect individual cells into modules. Laser welding enables the creation of busbar-to-cell connections that meet critically important electrical performance requirements while also offering unmatched production speed, reliability, and ease of automation.
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Battery Packs
Battery pack and tray welding encompasses two processes. First, making a high quantity of electrical connections to increasingly thick conductors, frequently of dissimilar or coated materials. Second, sealing the robust mechanical cases that enclose the battery itself. Laser welding offers the speed and reliability to create both high numbers of welds and strong, high-quality welds, even in reflective materials like aluminum.
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Electric Motors
Electric vehicle motors are designed with hairpin conductors that require several manufacturing steps. Laser ablation, or material removal, enables electric motor manufacturers to rapidly and reliably strip insulation coating from the hairpin ends. Once the underlying copper is exposed, laser welding is a high-speed method of creating low-resistance joints with high accuracy and virtually no spatter.
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Power Electronics
In addition to batteries, vehicle electrification requires additional electrical components such as inverters, control boxes, and power distribution units (PDUs) to handle the flow of electrical signals and currents to the drivetrain components. Fiber lasers enable the welding of the inter-component connectors and busbars to meet critically important performace requirements while also offering unmatched production speed, reliability, and ease of automation.
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Fuel Cells
Hydrogen fuel cells, an alternative to Li-ion batteries, are used to power a variety of systems including vehicles and other energy storage applications. Fuel cells rely on bipolar plates and MEAs as key components. Laser processing solutions are able to meet the demanding requirements of these components, offering precision, quality, and speed in applications including welding, slurry drying, cutting, and more.
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