Li-ion cells

Phil the drill

Esteemed Pedelecer
Jun 14, 2008
395
6
TR9
I've posted this before before and had no replies and it is now getting rather urgent.
Surely there must be someone in UK PLC who can spot weld tabs onto Li-ion cells? If so, I find it hard to believe that there isn't anybody on this forum who knows where :confused: .
Help please.
Phil.
 

z0mb13e

Esteemed Pedelecer
Jul 28, 2009
578
3
Dorset
You could try making a DIY capacitive welder - hook up a bunch of big capacitors to a DC supply, and a couple of welding probes and hey presto, battery tab welder.

Well ok I might be over simplfying a bit!

As for pack refurb I found these on google, they might be able to do what you want or if not they might be able to point you in the right direction.

DSM Technology's Custom Design and Build Services

Contact the Strikalite team

BatteriesPlus+ Battery Pack Refurbishment


p.s. I can't vouch for these sites, they were just a few of the ones that google threw up.
 

flecc

Member
Oct 25, 2006
52,817
30,381
Spot welding is very much a manufacturing process, and in Britain we seem to have largely given u making things. However, try a local car body repair specialist Phil, they may have the spot welding gear.

You can do it yourself easily if you have a usable car battery and a pair of goggles to protect your eyes just in case of any splatter.

Connect a couple of heavy cables to the charged car battery, old jump leads will do. Then clip the tag onto the end of the negative cable or pinch the tag against the cable end with pliers using one hand to make a good connection.

Now hold the positive end against the edge of the end plate of the cell you want to connect to and touch the negative connected tag accurately into place. It will instantly flash and weld into place so just as instantly lift away your positive connection to stop the current flow.

Since the connections are both on the same end plate no current will flow through the cell. Make sure you don't cross connect the battery cables together while welding of course.

You can practice this first on the end of an old tin can of course to perfect your technique and see if you are confident enough to do it on the cells.
.
 

Phil the drill

Esteemed Pedelecer
Jun 14, 2008
395
6
TR9
You could try making a DIY capacitive welder - hook up a bunch of big capacitors to a DC supply, and a couple of welding probes and hey presto, battery tab welder.

Well ok I might be over simplfying a bit!

As for pack refurb I found these on google, they might be able to do what you want or if not they might be able to point you in the right direction.

DSM*Technology's Custom Design and Build Services

Contact the Strikalite team

BatteriesPlus+ Battery Pack Refurbishment


p.s. I can't vouch for these sites, they were just a few of the ones that google threw up.
Thanks
I have thought about a DIY welder but I don't do enough to justify the cost. Getting decent hi-cap electrolytics (really need computer grade) is very difficult and expensive. Audio grade ones are very 'hit and miss.'
I looked on the web and somehow missed those sites.
Will give them a try.
Many thanks, Phil.
 

Phil the drill

Esteemed Pedelecer
Jun 14, 2008
395
6
TR9
Thanks Flecc. I think I'm not quite brave enough to risk it that way! z0mb13e found a couple of promising looking sites, so I'll give them a try.
Many thanks anyhow, Phil.