Solar container battery welding method

How are battery interconnects made?

Spot welding strips and tabs onto batteries in order to make battery interconnects and larger battery pack assemblies is a common production technique. Typically, battery interconnects are made from nickel strips, ideally designed with bifurcations and projections which are then resistance welded using parallel gap or step welding methods.

What is TIG battery welding?

The TIG battery welding process has been tested and proven with a number of high-integrity Lithium Ion designs with excellent electrical and mechanical results, using Nickel, Aluminium and Copper flat sheets to a maximum thickness of around 0.5 mm.

What is a non-contact welding process?

The process is non-contact, has no consumables, offers instantaneous welding once positioned at the weld point location, provides sufficient control over the process to size the weld nugget according to requirements, and provides a number of implementation methods that can be geared toward individual manufacturing requirements.

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.

What is laser welding & how does it work?

Laser welding enables joining of many materials and material combinations, can weld thick parts, and has no limitation on proximity of weld spots. There are two types of laser that provide solutions for battery applications: pulsed Nd:YAG and fiber. Both of these lasers offer different joining characteristics that can be selected as appropriate.

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.