A method for the reproducible and accurate determination of electrical resistances based on multi-layer joints in lithium-ion batteries

The transition from fossil fuels to renewable energy sources is significantly influenced by the development of energy storage systems such as batteries. One of the crucial steps in the production of lithium-ion batteries is the electrical connection of the individual electrodes by weld seams. Various joining processes, such as laser beam welding or ultrasonic metal welding, are used for this purpose. An important quality feature of the connections is a low electrical joint resistance, which is essential for reducing cell-internal energy losses and avoiding thermal inhomogeneities in the cells. The aim of this work was to determine the electrical resistance of the joint between a stack of foils and an arrester tab. For this purpose, a measuring method was developed and applied to different sample configurations. The influence of different probe tips on the measurement results was compared using single current collector foils and arrester tabs. The measurement of the electrical resistance was possible in the considered range with a maximum relative uncertainty of 2.38 %. Using the presented approach made it possible to evaluate the influence of the seam trajectory on the electrical resistance for cell-internal contacting. In addition, the measuring method is suitable for comparing different welding strategies and, thus, for designing the cell-internal joining processes regarding the resulting electrical joint resistances.