1. CCS Overview and Application Scenarios

CCS integrated busbar：Also known as battery cover assembly, its main application scenarios include new energy vehicles, energy storage equipment, grid energy storage, smart home and other fields. For example, in the grid energy storage system, CCS integrated busbar can realize the circuit connection and energy management of the battery pack, and improve the safety and stability of the system. In the field of smart home, CCS integrated busbar can be used in the battery module of smart home equipment to realize intelligent management and control of the equipment.

1. Signal acquisition components：This includes FDC (flexible circuit board), PCB (printed circuit board), FFC (flexible flat cable), etc.

2. Plastic structural parts：Plastic structural parts are mainly used to support and fix signal acquisition components and other components to ensure the stability and reliability of the entire system.

3. Copper and aluminum busbar：The copper-aluminum busbar is the conductive part of the CCS integrated busbar, which is used to achieve high-voltage series and parallel connection between battery cells. The copper-aluminum busbar has good conductivity and mechanical strength, which can ensure the efficient operation of the battery system.

2. Brief Introduction of FDC

FDC (Flexible Die-cutting Circuit) is a flexible circuit board with PI/PET film and copper foil as the base material. The circuit formation is based on the cutting process of the adhesive tape die-cutting industry using a die (round knife or flat knife). Like FPC, FDC also has the characteristics of being able to bend, fold, and wind freely, and can be moved and stretched in three-dimensional space at will. In theory, it can replace FPC, effectively shorten the production cycle, reduce costs, and the process is more environmentally friendly.

3. FDC Advantages

Line width and line spacing: The line width and line spacing can reach 0.25-0.3mm;

Performance guarantee: The performance is equal to that of traditional FPC products, and the double 85 test 1000H has been completed;

Fuse: The line width and line spacing can reach 0.15 in some locations, thereby realizing the function of the fuse;

Compared with FPC, the length of FDC can be more than 2 times that of FPC, and the maximum length of FDC can be 2-3 meters.

4. Gongda Green Laser Application in CCS-FDC Cutting

Use Gongda fiber green laser to perform FDC line cutting. The minimum line width at the fuse position is ≥150um, the cutting efficiency is ≥1000mm/s, and the base film is not damaged during cutting.

5. CCS-FDC welding application

Use Gongda green laser to conduct welding test;

• 35~70um rolled copper and FDC welding, peeling force ≥20N, no damage to the bottom insulation layer;

• 35~70um rolled copper and aluminum bar welding, peeling force ≥30N.

Copper and aluminum welding

Copper and FDC welding

6. Comparison between green laser processing and traditional processing

Green laser cutting features：

• The cutting section is smooth, without burrs, dislocation and other phenomena;

• Laser cutting is non-contact cutting, and there is no need to replace consumables such as blades;

• It has great advantages for special-shaped, irregular shapes and horizontal cutting;

• The laser cutting seam width is narrow, saving copper foil resources;

• Laser cutting can achieve real-time power adjustment according to different copper foil thicknesses;

• It can also cut with base film;

Green laser welding characteristics：

•Stable welding effect, controllable FDC insulation layer; copper absorbs about 40% of 532nm light;

•Small welding spatter;

•Small thermal impact;

7. Laser Introduction

Good beam quality: The laser beam produced by the green fiber laser is of high quality, with a small spot and high beam quality, which is suitable for precision machining and high-precision applications.

High energy efficiency: Compared with traditional gas lasers, green fiber lasers have higher energy efficiency, lower energy consumption, energy saving and environmental protection.

Strong stability: Green fiber lasers have good working stability, stable beam quality and power output during operation, and are suitable for long-term continuous operation.

Easy to integrate: Green fiber lasers are small in size and light in weight, which are easy to integrate into various equipment and are widely used in medical, communication, material processing and other fields.

Tunability: The wavelength of green fiber lasers is usually around 532 nanometers, and the wavelength can be fine-tuned by adjusting the device parameters to meet the needs of different applications.

Long life: Green fiber lasers usually have a long life, low maintenance cost, and good economy.

In order to solve the pain points of severe spatter when welding high-reflective materials in the infrared band, Gongda Laser launched a 500W continuous green light laser that uses an all-fiber fundamental frequency plus an extra-cavity frequency doubling solution to achieve a continuous green light output of more than 500W. It has the advantages of high absorption rate, less spatter, high efficiency, high stability, and high beam quality. The laser can also provide a flexible transmission method coupled to the optical fiber, which is more convenient to match the automated control and is applied to the welding process of high-reflective materials such as copper. Due to its good output power stability, excellent beam quality, and high absorption rate of high-reflective materials, especially copper, it is expected to be used in 3D printing of pure copper materials.

Features:

1. Suitable for welding copper and other high-reflective materials

2. Compared with infrared laser, there is almost no flying debris in the welding process

3. Faster absorption and high repeatability

4. Higher absorption rate, the copper welding process is completely stable and reliable

》About Gongda Laser

Shenzhen Gongda Laser Co., Ltd. is a young high-tech intelligent manufacturing enterprise, a national high-tech enterprise, and a Shenzhen specialized enterprise. Gongda Laser focuses on the research and development and manufacturing of high-power short-wavelength fiber lasers. It is committed to becoming an international first-line and domestic leading fiber laser supplier. It has completed the research and development and production of a series of core products such as "50-500W sub-nanosecond green laser", "100-3000W continuous green laser", and "200-1000W infrared nanosecond pulse fiber laser". The products are widely used in lithium batteries, photovoltaic cells, high-reflective metal 3D printing, semiconductors and other fields.