Energy storage welding welding head sticking copper sheet

Can a battery can be welded to a copper sheet?

As a stable welding connection of a 1.5 mm thick copper sheet (Cu-OF) to a 0.3 mm thick metal part (DC04, battery can) is not possible, but necessary, to reach the desired conducting cross-section of A = 50 mm 2, welding of a thin copper sheet (0.2 mm thickness, CuSn6) is used as the direct connection to the battery can.

Which welding techniques can be used for connecting battery cells?

Brass (CuZn37) test samples are used for the quantitative comparison of the welding techniques, as this metal can be processed by all three welding techniques. At the end of the presented work, the suitability of resistance spot, ultrasonic and laser beam welding for connecting battery cells is evaluated.

How is a PCM Weld done?

The welding is done while the cell is charged and filled with the cathode and anode material, the separator and the liquid electrolyte. The copper collector is also used to encapsulate the PCM, therefore the weld must be liquid-tight.

How are three welding techniques compared?

Additionally, the three welding techniques are compared quantitatively in terms of ultimate tensile strength, heat input into a battery cell caused by the welding process, and electrical contact resistance.

Are welds liquid-tight?

As the welds show air tightness and the viscosity of the PCM is much higher than the viscosity of air, the welds can also be considered liquid-tight. Nevertheless few welded samples showed leaking spots. The leakage in these cases can be traced back to inaccuracy in positioning of the seam.

Which parameter set has lowest welding depth?

As the parameter set with an energy per section of ES = 3 J/mm and A = 0.6 mm shows the lowest capability regarding the welding depth only the parameter set of A = 0.4 mm and A = 0.5 mm with ES = 3 J/mm were analyzed further.