Copper alloy battery tab welding for cylindrical lithium ion battery

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Application of cylindrical lithium-ion batteries

Cylindrical lithium-ion batteries are used in electric assist bicycles, and home appliances.
Furthermore, cylindrical lithium-ion batteries are also used in the backup power supplies (ESS, UPS) of data centers and the batteries
installed in 48V mild hybrid vehicles related to xEV.

Challenges of cylindrical lithium-ion batteries

The challenges for cylindrical lithium-ion batteries are increasing capacity and quick charging.
When assembling a cylindrical lithium-ion battery into one battery pack, multiple batteries are connected by a thin metal plate called a "battery tab".
Ni has been used as the battery tab uses nickel. However it has low conductivity and is expensive.
In recent years, "tin-plated copper alloys", which have high conductivity and are inexpensive, are attracting attention as a material to replace nickel.
By changing the battery tab to "copper alloy tab", it is possible to support large capacity and quick charging.

Image:Challenges of cylindrical lithium-ion batteries

To weld copper alloy tabs

Welding copper alloys with high conductivity requires higher current than nickel.
The conventional "transistor-type" welder, which is assuming to weld nickel up to 0.2 mmt, does not have enough current and weld time. Therefore, resistance welder with high capacity for the battery tabs are required.
The highly reliable inverter type resistance welder NRW-IN400PA provide total solution for the challenges of the batterie tabs.

About NRW-IN400PA / NT-IN8444B, an inverter type resistance welder for
battery tab welding?

Unlike conventional inverter-type resistance welders, NRW-IN400PA allows you to switch frequency between 2KHz, 4KHz, and 5KHz by reducing internal loss, as well as newly developed high-efficiency transformer, and the resolution of the weld time is as high as 0.2ms at 5KHz.
Since the frequency can be selected for each program number, it is possible to select the frequency suitable for the workpiece and obtain high-quality welding with little current ripple
Therefore, the high current required for welding copper alloy tabs can be output in a short time.
For detailed specifications, please see the product page.


Related video

Please check a video clip which explains copper alloy tab welding.
Please be careful for the volume adjustment as this movie contains sound.

Please click here if you are interested in battery tab welding other than copper alloy tab.

Copper alloy battery tab welding for cylindrical lithium ion battery

Joining MethodResistance Welding
Processing MethodMetal Joining
End ProductsBattery
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