Welding methods for electrical connections in battery systems

The demand for high energy battery assemblies is growing in sectors such as transportation. Alongwith it is the need for reliable, efficient and cost-effective ways to electrically connect the batteries toensure their performance. Battery cells are most often put into modules or packs when produced forelectrically driven vehicles. The variable of greatest influence when welding battery packs is thecontact resistance between the cell and the connection tab. It is crucial to minimize this variable asmuch as possible to prevent energy loss in the form of heat generation. The purpose of this project is to conduct a comparative literature study of different weldingtechniques for welding batteries. The compared techniques are resistance spot welding, laser beamwelding and ultrasonic welding. The performance was evaluated in terms of numerous factors such asproduction cost, degree of automation and weld quality. All three methods are tried and proven to function in the production of battery applications. Eachmethod has separate strengths and limitations which makes them complement each other. Thus, it isimportant to look at several factors when deciding which welding technique is the most suitable forthe desired application. The scale of production, economical aspects as well as battery cell geometrywere concluded to be the most important in making this decision