Turnkey Solution for New Energy Intelligent Equipment
A toroidal laser beam (annular laser) uses advanced optics to reshape a standard Gaussian beam into a hollow-ring energy distribution. Unlike conventional lasers that concentrate heat at the center, toroidal beams distribute energy uniformly along a ring periphery. This design stabilizes the welding keyhole and molten pool, minimizing defects like spatter—especially critical for high-reflectivity metals (copper, aluminum) common in battery modules.
Spatter Suppression (>90% Reduction)
Concentric ring energy balances vapor pressure and melt flow, eliminating micro-spatter that contaminates battery cells and causes short circuits.Enhanced Penetration Consistency
Uniform heat distribution achieves ±0.03mm tolerance in copper/nickel joints, reducing porosity to <0.5% vs. 15% with Gaussian beams.
Adaptability to Reflective Materials
Outer-ring energy preheats surfaces to reduce reflectivity, while inner rings melt materials—boosting copper welding efficiency by 40% at identical power levels.
High-Speed Automation Compatibility
Integrates with CCD vision systems and real-time focal monitoring, enabling ±0.02mm alignment accuracy at 2.5s/piece.
|
Component |
Toroidal Laser Role |
Benefit |
|
Cell-to-Busbar |
Welds copper/aluminum tabs to electrodes |
Lowers resistance, prevents hot spots |
|
Module Interconnects |
Joins battery clusters with hermetic seals |
Ensures leak-proof cooling channels |
|
Inverter Busbars |
Bonds thick copper plates in power converters |
Withstands 500A+ current surges |
|
Housing Seals |
Welds aluminum enclosures with zero particulate generation |
Meets IP67 safety standards |
Real-World Impact: A TOP 10 battery OEM reduced porosity in 280Ah LFP modules from 8% to 0.3% using toroidal welding, cutting rework costs by 35%.
|
Criterion |
Key Metrics |
Industry Benchmark |
|
Optical System Maturity |
Beam stability, adjustable ring width (20–300μm) |
Multi-ring dynamic modulation |
|
Process Database |
Pre-validated parameters for Cu/Al/Ni joints |
≥50 material recipes |
|
Automation Integration |
Compatibility with robotics/EOL systems |
≤5min model changeover time |
|
Technical Support |
Spatter analysis, real-time remote diagnostics |
24h emergency response |
Huiyao Laser pioneers end-to-end toroidal laser solutions for energy storage manufacturing:
Patented Ring-Core Optics: Dynamic beam shaping for spatter-free welding at 200mm/s, even on 0.1mm copper foils.
Turnkey Production Lines: Integrates magnetic suspension transport (±0.01mm precision) and AI-based weld monitoring, boosting OEE to 89%.
Global Support: 12+ technical centers offer process validation and 72h on-site emergency support.
Case Study: Enabled a 300% throughput increase for a 20GWh ESS factory while reducing scrap rate to 0.1%.
Email: yaolaser@huiyaolaser.com
Head Quarter Address: Huiyao Laser Technology, Building 2, Langxu Industrial Park, Guanlin Road, Science Park Street, Luolong District, Luoyang City, Henan Province, China
Research&Development Center: Room 901-9,Building B1, Phase 1, Southern Area, Baoneng Science and Technology Park, Qinghu Industrial Zone, Gangtou Community, Batian Street, Longgang District, Shenzhen City.
