Welding method of energy storage battery

How do you Weld a battery?

Batteries, integral to the functioning of devices like electric vehicles, laptops, smartphones, and solar panels, consist of multiple cells storing and delivering electrical energy. Joining these cells requires welding, and two prevalent methods in battery applications are spot welding and laser welding.

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.

Can a battery cell casing be welded?

The findings are applicable to all kinds of battery cell casings. 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.

Why do EV batteries need to be welded?

Welding technology used for EV battery assembly must minimize the cell-to-tab electric resistance for top battery performance and safety . Thermal runaway is always a hazard given the hyper energy density of EV batteries . Improper connection escalates this risk by increasing the cell-to-tab resistance .

Which weld is best for EV battery packs?

Use minimal weld energy to prevent excessive heating of the internal cell separator . High quality welds are of uniform width and have no gaps. Thin welds are more suited for EV battery packs. Thicker ones can penetrate the casings. Proper welds address the following welding challenges & :

How a cell connection affects the performance of a battery system?

Every single cell connection influences the functionality and efficiency of the whole battery system. Resistance spot, ultrasonic or laser beam welding are mostly used for connecting battery cells in the production of large battery assemblies.