Tab Welding
Definition
Cell interconnection method using resistance or laser welding to attach nickel tabs or bus bars to cell terminals. Common for prismatic and pouch cells.
Why It Matters
- Most common interconnection method for mass production
- Suitable for prismatic and pouch cell formats
- Faster than wire bonding for high-volume manufacturing
- Creates rigid connection that transmits vibration stress
Common Pitfalls
- Weld spatter or heat damage to cell seal
- Inadequate weld strength leading to connection failure
- Vibration fatigue at rigid weld joints
- Not optimizing tab thickness vs. flexibility tradeoff