This paper presents a comprehensive overview on joining battery cells by resistance spot, ultrasonic and laser beam welding. The specific features, advantages and dependencies of each welding technique for connecting cells are discussed.
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Battery energy storage systems (BESSs) are advocated as crucial elements for ensuring grid stability in times of increasing infeed of intermittent renewable energy sources (RES) and are
Brass (CuZn37) test samples are used for the quantitative comparison of the welding techniques, as this metal can be processed by all three welding techniques. At the end of the presented work, the suitability of resistance spot, ultrasonic and laser beam welding for connecting battery cells is evaluated.
The findings are applicable to all kinds of battery cell casings. Additionally, the three welding techniques are compared quantitatively in terms of ultimate tensile strength, heat input into a battery cell caused by the welding process, and electrical contact resistance.
Within any battery storage, the smallest energy storing component is the battery cell or short cell. Whereas for mobile devices, e.g., laptops, only a few cells are combined, in large battery assemblies up to several thousand cells have to be connected.
Further increasing the welding energy leads to electrode sticking and significant expulsion of bulk material , , , . Fig. 6. Electrical contact resistance and ultimate tensile force as function of welding energy.
The new manufacturing tech-nologies such as high-efficiency mixing, solvent-free deposition, and fast formation could be the key to achieve this target. Besides the upgrading of battery materials, the potential of increasing the energy density from the manufacturing end starts to make an impact.
In large battery assemblies, which are integrated, for example, in electric vehicles or stationary storage systems, up to several thousand single battery cells are connected together. Every single cell connection influences the functionality and efficiency of the whole battery system.
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