"Ugh - my battery just died!" "Can I use your charger?" "Mind if I recharge my phone?" Batteries are everywhere, and we've become increasingly dependent on them in many aspects of our daily lives: portable electronic devices, cordless power tools, energy storage, and hybrid and EV cars. Thus, the demand to manufacture batteries that meet or exceed quality and production requirements for these products, is great.
Resistance spot welding, micro TIG welding, and laser welding processes all enable high quality volume production. The selection of one technology over another is usually made based on the application's specific requirements and the alignment of the technology to these needs.
So, what battery welding technologies are available and what are the benefits of each?
Technology selection depends in large part on the application it’s used for. Here are a few important rules that should be followed when using a technology for a particular application:
Selecting the most suitable technology and process for battery pack manufacture
Selection of the most suitable technology and process is based on two main factors: tab thickness and material.
Resistance spot welding, micro-TIG welding, and laser welding technologies each have specific features that align well to these joining needs. A clear understanding of the technologies and application is needed to implement an efficient and reliable production welding system. The following diagram shows where each of the technologies fit for tab thickness and production throughput. For example, resistance welding is an excellent choice for thinner tabs and medium processing speed for hand tool packs, while laser welding is a better choice for thicker copper and aluminum tabs such as those used in electric vehicles. Micro-TIG is best suited for tab-to-busbar welding for low to high capacity packs.
For more information read Battery Welding Solutions Using Laser & Resistance Technologies.