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Battery Packs

Batteries come in many different shapes and sizes, ranging from miniature cells used to power hearing aids and watches, to battery banks that provide standby power for telephone exchanges and computer data centres.

There are many joining requirements in battery manufacturing; these include both internal and external connections, as well as can or fill plug sealing. Laser welding is often used to join the internal electrode materials that make up the internals of the cell. These are typically constructed of thin foils of copper and aluminium. The remaining joints, including connections inside the can and external terminal tab connections, are suited to both resistance and laser welding. The decision to use one technology over another is determined both by the type of weld required and production requirements, such as high volume and material compatibility.

MacGregor Welding Systems possesses a vast experience in welding batteries, including Lithium Ion, Nickel-Metal Hydride, Lead Acid, Nickel-Cadmium and Alkaline in many different sizes: N - all sizes, AAA (LR03 / R03) - all sizes, AA (LR6 / R6) - all sizes, Sub C & C, D. Our expertise and combined technologies are used in many applications throughout the battery manufacturing industry. The technologies used for battery pack welding include projection welding of battery caps, resistance welding of battery tabs to coin cells and micro TIG welding battery tabs to produce battery packs. The end product is extensively used for applications such as power tools, medical instruments, mobile devices, electric power trains in hybrid and electric vehicles, wind turbines and many more.

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