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Amada Miyachi's experienced application engineers provide customers with the equipment match from our wide range of products that best addresses a specific application need. FREE sample evaluations - part design, material selection, and know-how - conducted in one of our eight dedicated labs maximizes component manufacturability.

Industries


Batteries

For each type of battery manufactured, Amada Miyachi offers a production solution: resistance welding, laser welding, laser marking or laser cutting. We have in-depth knowledge and experience for each category and application, for example, laser welding of dissimilar metals for battery tab welding and resistance welding for tab design optimization. Our in-house application labs enable proven processes to be delivered with optimized systems.

Amada Miyachi has extensive experience welding and marking batteries:

Cylinder batteries

  • Battery tab welding (resistance or laser)
  • Weld short circuit protection (resistance or laser)
  • Weld internal connections (resistance or laser)
  • Laser seam weld battery can
  • Laser mark battery can

Prismatic batteries

  • Battery tab welding (resistance or laser)
  • Laser weld fill port
  • Laser weld terminal
  • Weld internal connections (resistance or laser)
  • Laser seam weld battery can
  • Laser mark battery can

Pouch batteries (such as LiPoly)

  • Battery tab welding (laser)
  • Laser cut electrodes

Ultracapacitor batteries

  • Laser weld fill port
  • Weld internal connections (resistance or laser)
  • Laser seam weld battery can
  • Laser mark battery can

There are many materials joining requirements in battery manufacture. Depending on the size, type, and capacity, these include both internal and tab-to-terminal connections, can and fill plug sealing, and external connections. Several joining options can be considered including ultrasonic , resistance, and laser welding. Ultrasonic welding is most often used to join the internal electrode battery materials which are typically constructed of thin foils of copper and aluminum. The remaining joins - including connections inside the can, and external terminal tab connections - are suited to both resistance and laser welding. The decision to use one technology or the other is determined both by the type of weld required and production requirements. Laser welding is the joining technology of choice for can and plug applications (seam sealing).

Resistance welding is a well-established battery spot welding technology - 40 years old - and has been used in the battery industry for almost as long. Since then, advances in battery spot welders have given users improved capabilities to control different aspects of the process. The introduction of DC inverter power supplies with closed-loop control, for example, enabled welding engineers to accommodate changes in the secondary loop to address resistance. Similarly, polarity switching for capacitive discharge power supplies to enable weld nugget balancing, as well as the addition of electrode force measurement and displacement, provides manufacturers with more tools to ensure weld quality.

A typical resistance battery spot welder setup would consist of a battery spot welder power supply like Amada Miyachi's capacitive discharge spot welders paired with a Thinline weld head, or our linear dc micro spot welder paired with our new eletromagnetic low force weld head.

Laser welding was introduced to the manufacturing marketplace in the mid-1980's. As the technology has matured, and the awareness spread, laser welding has become an established process. Today, it is just another tool in the manufacturing engineer's toolbox, implemented as needed. The laser produces a high intensity beam of light that can be focused to diameters as small as 0.01". The concentration of light energy is able to melt metals rapidly, instantaneously forming a weld nugget. The non-contact process has no consumables, provides extremely tight control over the process to size the weld nugget according to requirements, and allows for implementation methods that can be geared toward the specific manufacturing requirements. Laser welding enables joining of many materials/combinations of materials, can weld thick parts, and has no limitation on proximity of weld spots.

For more information read the Battery Industry Capabilities Brochure, Battery Welding Solutions Using Laser & Resistance Technologies, Resistance Welding Tips for Getting Better Performance and Higher Currents from Battery Packs, our blog, or Contact us for a personal consultation or free sample evalution.

  • Photo of Battery Pack Welding

    Battery Pack Welding

  • Photo of Coin Cell Fabrication

    Coin Cell Fabrication

  • Photo of Leak Caps

    Leak Caps

  • Photo of Laser Marking Battery Cans

    Laser Marking Battery Cans

  • Photo of Lead Acid Battery Welding

    Lead Acid Battery Welding

  • Photo of Conductive Tab

    Conductive Tab

  • Photo of Lead Acid Battery

    Lead Acid Battery

  • Photo of Plug Weld

    Plug Weld

  • Photo of Seam Seal Aluminum

    Seam Seal Aluminum