Lithium battery welding – Common methods and optimization

This article collates several common methods of lithium battery welding, as well as common problems and repair methods. And the development trend of lithium battery welding.
Table of Contents

Principle of lithium battery welding

In lithium battery production, the connection between the battery pole lug and the electrolyte conductor is one of the most important processes. This welding process usually uses high-frequency pulsed arc welding technology, through the application of instantaneous high temperature and high voltage current, so that the electrode and the lead quickly melt and form a strong connection. Controlling welding parameters is the key to ensure welding quality.

Welding parameters such as temperature, time and pressure need to be tightly controlled to ensure that the temperature and pressure in the lithium battery welding process can reach the required level without adversely affecting the material and structure inside the battery. This can ensure the solidity of the welding points and the good performance of the electrical connection, thereby improving the service life and safety of the lithium battery.


6 methods for lithium battery welding

Common lithium battery welding methods include the following:

1. Resistance welding:

This is a common lithium battery welding method, through the current through the welding material to generate heat, so that the welding material instantly melted, forming a welding point. In lithium battery manufacturing, resistance welding can be used to connect the positive electrode, the negative electrode and the conductive part of the battery together.

2. Laser welding:

Laser welding is a method of using a high-energy laser beam to heat the welding part, so that the welding material instantly melts and forms a welding point. In lithium battery manufacturing, laser welding is usually used to connect the components and components of the battery, which can achieve high precision and high efficiency lithium battery welding.

3. Spot welding:

Spot welding is the use of current through the electrode to produce instant high temperature, the welding material will instantly melt and form a welding point method.In the manufacture of lithium batteries, the lead wire can be connected to the pole lug of the battery using spot welding technology.

4. Pull welding:

Pull welding is a lithium battery welding method, by applying heat and tension in the welding part, so that the welding material is instantly melted and connected. In lithium battery manufacturing, pull welding is usually used to connect the lead and pole lug of the battery, as well as the external wire connecting the battery.

5. Ultrasonic welding:

Ultrasonic welding is a method of using the heat generated by ultrasonic vibration to carry out lithium battery welding. In lithium battery manufacturing, ultrasonic welding is often used to connect the battery’s leads and pole lugs, as well as other components that require micro-size welding.

6. Hot pressure welding:

Hot pressure welding is the use of heat and pressure to melt the welding material and connect the method. This method is usually suitable for occasions where welding needs to be performed on a larger area, which can ensure the uniformity and firmness of the welding points.

Each of these methods has advantages and disadvantages, and the choice of the appropriate lithium battery welding method depends on the specific requirements of the lithium battery, material characteristics and production process. In practical applications, the appropriate welding method is usually selected according to the specific production needs and technical conditions.


Common problems and repair methods of lithium battery welding

  1. Insufficient strength of welding workpiece: it may be due to incorrect welding parameters or welding material quality problems. You can adjust lithium battery welding parameters, such as welding time, current and voltage, and ensure that high-quality welding materials are used.
  2. There should be no splash during welding: this may be due to high welding current or impurities on the welding surface.You can reduce the lithium battery welding current and clean the welding surface to ensure that there are no impurities on the surface.
  3. The power indicator is on, and the workpiece is pressed and not welded: it may be due to the failure of the lithium battery welding equipment or poor contact.You can check the power of the welding equipment and wiring, to ensure normal work.
  4. Serious solder joint indentation and extrusion: this may be due to excessive welding pressure or unreasonable welding head design. You can reduce the pressure on lithium battery welding and optimize the weld head design.
  5. The solder joint is not melted through, the nucleus is formed poorly or not formed: it may be due to the welding temperature is not high enough or the welding time is not long enough. You can increase the temperature and time of lithium battery welding to ensure that the solder joint is fully melted and a good core is formed.


Development trend of lithium battery welding

  1. Automation and intelligence: As the level of industrial automation increases, electrode welding equipment will become more intelligent and automated, including the use of machine vision, machine learning and automatic control technology to improve the consistency and efficiency of lithium battery welding.
  2. High speed and high efficiency: With the increase of lithium battery production, electrode welding equipment needs higher production efficiency, so the future development trend will be to achieve higher speed and higher efficiency lithium battery welding.
  3. Green environmental protection: With the enhancement of environmental awareness, electrode welding equipment will tend to be more environmentally friendly, energy saving and low emissions, using more environmentally friendly lithium battery welding process and materials.
  4. High precision and high quality: With the increasing demand for quality of battery products, electrode welding equipment will be developed in the direction of higher precision and higher quality lithium battery welding to ensure the reliability and consistency of lithium battery welding points.
  5. Multi-functional: The future electrode welding equipment may develop in the direction of multi-functional, and can adapt to the welding needs of different specifications and types of battery products to improve the flexibility and applicability of the equipment.


In general, the development trend of electrode welding equipment will be automation, intelligence, high speed and high efficiency, environmental protection and energy saving, high precision and high quality and multi-functional. I hope the suggestions above have been helpful. If there are other problems, it is recommended to seek a professional welding engineer for on-site inspection and adjustment.

Thanks for browsing, you must also be interested in the top 10 lithium battery production equipment manufacturers, you can click on the link to find out. For more information about lithium batteries, please refer to lithium battery technology, lithium supplement, lithium battery charging.

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