Laser welding of battery module enclosure components

1 . A through transmission laser welding system for a battery module enclosure, comprising:

a first battery module enclosure component;

a second battery module enclosure component that interfaces with said first battery module enclosure component; and

a laser source that focuses a laser beam on a junction between said first and second battery module enclosure components in order to form a weld between said first and second battery module enclosure components.

2 . The through transmission laser welding system of claim 1 wherein said first and second battery module enclosure components comprise polymeric thermoplastics.

3 . The through transmission laser welding system of claim 1 wherein a wavelength of said laser beam is between 800 nm and 1100 nm.

4 . The through transmission laser welding system of claim 1 wherein said first battery module enclosure component is transmissive to a wavelength of said laser beam and said second battery module enclosure component is opaque to a wavelength of said laser beam.

5 . The through transmission laser welding system of claim 1 further comprising a laser absorbing coating that is applied at an interface between said first and second battery module enclosure components, wherein both said first and second battery module enclosure components are transmissive to a wavelength of said laser beam.

6 . The through transmission laser welding system of claim 1 wherein said laser source includes a plurality of laser sources that are arranged to continuously illuminate a predetermined area of said junction.

7 . The through transmission laser welding system of claim 6 further comprising a masking curtain that is located adjacent to said junction and that selectively filters said laser beam.

8 . The through transmission laser welding system of claim 1 wherein said laser source includes a single laser source that is scanned across said junction in order to form said weld.

9 . The through transmission laser welding system of claim 1 wherein said laser source includes a single laser source and an optical mirror that disperses said laser beam in order to continuously illuminate a predetermined area of said junction.

10 . The through transmission laser welding system of claim 9 further comprising a masking curtain that is located adjacent to said junction and that selectively filters said laser beam.

11 . The through transmission laser welding system of claim 1 wherein the battery module enclosure houses battery cells for a hybrid electric vehicle.

12 . A method for operating a through transmission laser welding system for a battery module enclosure, comprising:

providing a first battery module enclosure component;

providing a second battery module enclosure component;

interfacing said first and second battery module enclosure components;

focusing a laser beam on a junction between said first and second battery module enclosure components; and

forming a weld between said first and second battery module enclosure components at said junction.

13 . The method of claim 12 wherein said first and second battery module enclosure components comprise polymeric thermoplastics.

14 . The method of claim 12 wherein a wavelength of said laser beam is between 800 nm and 1100 nm.

15 . The method of claim 12 wherein said first battery module enclosure component is transmissive to a wavelength of said laser beam and said second battery module enclosure component is opaque to a wavelength of said laser beam.

16 . The method of claim 12 further comprising applying a laser absorbing coating at an interface between said first and second battery module enclosure components, wherein both said first and second battery module enclosure components are transmissive to a wavelength of said laser beam.

17 . The method of claim 12 further comprising:

generating said laser beam with a plurality of laser sources; and

arranging said plurality of laser sources to continuously illuminate a predetermined area of said junction.

18 . The method of claim 17 further comprising:

locating a masking curtain adjacent to said junction; and

selectively filtering said laser beam with said masking curtain.

19 . The method of claim 12 further comprising:

generating said laser beam with a single laser source; and

scanning said laser source across said junction in order to form said weld.

20 . The method of claim 12 further comprising:

generating said laser beam with a single laser source; and

dispersing said laser beam with an optical mirror in order to continuously illuminate a predetermined area of said junction.

21 . The method of claim 20 further comprising:

locating a masking curtain adjacent to said junction; and

selectively filtering said laser beam with said masking curtain.

22 . The method of claim 12 further comprising housing battery cells for a hybrid electric vehicle in the battery module enclosure.