Energy storage module extrusion welding tooling requirements

What are the materials joining requirements for battery manufacturing?

There are a number of materials joining requirements for battery manufacturing, depending on the specific type, size and capacity of the battery. Internal terminal connections, battery can and fill plug sealing, tab to terminal connections, and external electrical connections are a few key examples.

What is ultrasonic welding?

Ultrasonic welding is commonly used for the joining of the internal electrode battery materials, which are usually constructed of thin foils of aluminum and copper. The remaining joining requirements – including the connections inside the can, and external terminal tab connections – are well suited to resistance, microTIG, and laser welding.

Do weld tabs require heat input control?

Welding tabs or terminal connections to buss bars generally does not require as much penetration of heat input control as the tab to terminal welds. The materials, material thickness and combination of materials determine the best welding technique.

What is tab to terminal welding?

Avoiding penetration of the can and overheating the battery are important aspects of tab to terminal welding. Welding tabs or terminal connections to buss bars generally does not require as much penetration of heat input control as the tab to terminal welds.

What are the important aspects of Tab welding?

From a welding perspective, the important aspects of tab welding are the thickness and material of both the tab and the terminal. Resistance welding is extremely well suited to welding nickel tab material up to 0.015-inch thickness, and nickel or steel clad copper tab material to around 0.012-inch thickness to a wide variety of terminal materials.

What materials can be welded with laser welding?

For tab and buss bar joining, laser welding offers a high degree of flexibility, welding both thin and thick tab materials, and materials such as copper, aluminum, steel and nickel as well as dissimilar material combinations. Two example welds are shown in Figure 4.