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A power battery is the smallest unit of a power battery that consists of countless individual cells combined in a certain number and requirements to form a complete battery pack. So how is the battery pack specifically composed of battery cells? Specifically, a battery module is composed of several battery cells assembled and welded in parallel to form a PACK module; By connecting several battery modules in series to communicate a battery unit;

The on-board power supply usually exceeds 300V and 200A. The basic method now is to connect individual batteries 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 a new energy vehicle, which provides "energy" for the operation of the entire vehicle. We can briefly understand which systems are composed of a power battery PACK assembly, and what parts are each system composed of? In order to provide a more intuitive understanding of battery PACK, take the PACK of the Audi A3 Sportback etron hybrid car as an example. Generally speaking, the electric vehicle power battery pack consists of the following components: 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" 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 series parallel lithium battery pack, including battery packs, busbars, soft connections, protective plate packaging, plastic brackets, and other auxiliary materials, which together form a PACK. The system utilizes a mechanical structure to connect numerous individual cells in series and parallel, and considers issues such as mechanical strength thermal management, BMS matching, etc. Its main technical aspects are reflected in the overall structure, design, Welding and processing process control protection level, active thermal management system, etc.

CCS is an essential part of the battery pack process.

CCS (Cells Contact System) products are composed of FPC, plastic structural components, copper aluminum bars, etc. New energy vehicle power batteries are generally composed of multiple battery modules, with a single battery module corresponding to one CCS. One CCS is generally configured with 1-2 FPCs, and CCS combines plastic structural components, copper aluminum bars, and other structural components. In the field of power battery application, FPC is mainly used for replacing traditional wiring harnesses in the pack process to assist in information collection of battery packs.

When welding the power battery module FPC, the welding material involves nickel and copper plating nickel, mainly nickel aluminum welding. During welding, there are easy phenomena such as false soldering, welding penetration, explosive points, and welding deviation, which are specifically manifested as:

Different types of metals have different melting points: when low melting point materials melt, high melting point materials are still in a solid state. At this time, the melted materials are easy to penetrate into the grain boundaries of the overheated zone, causing the loss of low melting point materials, burning and evaporation of alloy elements, and causing changes in the chemical composition of the weld seam, 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 when the molten pool crystallizes. Due to different stress states on both sides of the weld, it is easy to cause cracks in the weld and Heat-affected zone, and even lead to the peeling of weld metal and base metal;

The thermal conductivity of the material is different from the specific heat capacity: it leads to the deterioration of the crystallization condition of the weld metal, coarse grains, and affects the wettability of refractory metals;

Dissimilar metal welding is prone to produce intermetallic compounds, and at the same time, structural changes occur, leading to the decline of mechanical properties of welded joints, especially cracks in the Heat-affected zone.

In addition, the thermal physical parameters such as linear expansion coefficient, thermal conductivity and specific heat capacity of materials change with temperature, which makes the laser welding process of dissimilar metal materials more complex.

Therefore, the high-quality power battery FPC welding process not only solves the problems of dissimilar metal welding series, but also improves the automation, intelligence, and efficiency of FPC welding. At the same time, it must avoid problems such as false soldering, solder penetration, burst points, and welding deviation.

Laser equipment manufacturers have launched corresponding laser welding equipment to meet the laser welding needs of CCS components. Its welding performance and quality are good, and it has been well received and consistently praised through practical applications by end customers.

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