Is there any high current pouch battery that are size 60mmX80mm maximum thickness 21mm for a battery operated tab welder

[sam_sam_sam]

I have a battery operated tab welder and the battery does not have enough current for the battery tab welder because after about 30 welded it does not have the same current output it voltage has gone down by at least 0.500 volts or maybe a more than that

I can fit 21700 battery cells in the enclosure it is very tight fit for four of them that are 35 amp high current capacity 35X4=140 high current output this should work a lot better than what is installed right now

I tested the battery cells there are installed right now and they are testing good with no issues that I can see
Parameters are as follows

charging current 2 amps
discharging current 2 amps

but these battery cells are not high current version and can see why the voltage drops so fast in this device it actually has a voltage meter read out and seems to be fairly accurate from what I can determine

My only issue with doing this modification is I want to fuse each individual cell to maximum of 20 amps each but the size of the fuse can not be very big because of space constraints I think I might use automated type of fuses and put individual tabbing to each of the screws on the circuit board

Dose anyone have any concerns about doing this modification to this battery operated tab welder if so please let me know so I can make a decision about safety and other issues that you can think of

one note putting four battery cells in the enclosure it does make weight about twice the amount of the original battery cells that are in there now

[sam_sam_sam]

Update on the test that was ran on some 18650 high current capability and you loose about 330 milliamperes hours of capability when going to a higher current level interesting results I going to run this test again but this time at 3 amp load and see how much more milliamperes are lost at this current level these are 3 amp hour battery cells

There is a test that I going to run but I have to make a testing jig that has a cooling fan setup that keeps the battery cell from overheating and having a thermal runaway situation from happening but this test will be ran at 10 amps but I first have to build the jig first

[stj]

3A cells?
that in itself is interesting, i have not seen high current 18650's better than 2400mAH

[sam_sam_sam]

Yeah Samsung has some 18650 that 2900 to 3100 milliamperes hours at 25 continue current draw according to the data sheet they seem to be decent battery cells the charging and discharging cycle graphics curves and very good for a 3 amp hour battery Battery Hookup had them at a special price they were slightly used battery cells and they tested this way I just had not gotten to using them until just recently because of needing some 18650 high current capability for the battery tabbing welder that you recommended to in fact I just ordered another one because after testing it on a couple of battery packs I going to see if I can put four battery cells in the enclosure instead of the foam pads that are taking up the with just two battery cells originally

I will pay very close attention to internal temperature because it shows this and the battery voltage as well

While I sorting out some containers today I found some thicker tabbing that I going to try use on these battery cells if the welder will weld them I will probably have to put it at the maximum setting on a battery cell that is not good anymore so if I blow a hole in it oh well shit happens

Other wise I going to fire up the heavy duty battery tabbing machine with a better quality controller board but this might not happen until next weekend if I have to go this route

[sam_sam_sam]

I have another battery operated battery tab welder and the battery in it is one that is a self discharging syndrome and I thought okay let me charge it up and run a test on 2 amp load and the discharge graph curve looks like shit is very steep in nature not good at all stop the test after two minutes and just recharge it and used it seems to work ok I had a paying customer that needed some CNC machine memory backup battery replaced but the replacement battery cells came with very short battery leads and his machine needed the long cables from the old battery cells one replacement original battery pack is over $230.00 and the replacement battery cells were $45.00 and two hours to do 6 battery ( which is two battery packs ) cells because I also had re-tab the battery cells because the tabbing used on the replacement battery cells the solder would not stick and was burning up the flux I have no idea what type of tabbing material was used I have seen this happen on pouch battery cell terminals before and you have to weld a type solder tabbing material so you can solder wires to them

[stj]

try using solder with Halide in the flux.

[sam_sam_sam]

try using solder with Halide in the flux.

What is a good brand to use for this purpose thanks

[sam_sam_sam]

Battery pack for the battery operated battery tabbing machine I am torcher testing this battery pack

I finally put together the 21700 battery cells 1S4P configuration and now I am testing the battery pack at 10 amp charging and 10 amp discharging cycle and let see how warm it gets doing this type of testing which I not done this high of amperage on a battery pack in quite a while

[sam_sam_sam]

Here is the battery pack for the battery operated tab welder machine
With the charging current only being 1.10 amp it going to take about 12 hours to charge completely up
With the battery voltage only being 3.4 volts it saying that the battery pack is low and turning off by itself

From what I see here I am not going to let the voltage go below 3.8 volts because of how long it takes to charge up completely

The test done on this battery pack is as follows
charging current 10 amps
discharging current 10 amps

The charging and discharging graphs look very good for testing the battery pack at 10 amps took a little bit over an hour to complete the discharging test which is what I expect to see

These battery cells are high current capacity battery cells 35 amps continuous loading which is 140 amp capacity and in pulse mode it would still have more to spare than 140 pulse amps

According to the battery tabbing machine current was averaging around 200 amp pulsed current

One note it is not easy to drill a hole into the tabbing material you have to use a paint stick and a piece of wood and sandwich the tabbing material in between the wood sandwich to drill into it for best results

So this project is complete and I am very pleased with the way it looks and turned out looks very professional job

[sam_sam_sam]

Well things did not go well with this modification it charged up ok but trying to weld with it is a hole another story unfortunately when you try to weld with it shut off and you have to restart it again and it lost all of the parameters which tells me that the battery connections are not good enough for very high current so I have to rethink how I am going to do these connections and or order the pouch battery cells for it which I am not really thrilled about doing at all

[sam_sam_sam]

Well I decided to do a test on the battery pack at 10 amps and found the following

First let say that I understand why they use pouch battery cells in these devices because of voltage and current losses using tabbing material you have to keep the runs very very short because you generate heat in the tabbing material I have a solution for this problem even though the pouch battery cells that I going to is way over kill but with two of these battery cells it would be able to supply 400 continuous amps and 800 pulse amps at one second intervals

The biggest issue with using these battery cells is that they have to be under compression this is a much according to the data sheet I can accomplish this with the pouch battery holders that come with the battery cells and two pieces of cutting board as the enclosure for the battery cells and this will give me a mounting device to use in a metal enclosure to house the battery cells

Now if I could find a prisms type of battery cells the right side length and width and depth that would fit in the battery operated battery tabbing machine I would prefer to use this instead but I am not sure how to go about finding something like this

If anyone has any suggestions on how to go about doing this please feel free to chime in I am open for suggestions

[sam_sam_sam]

Actually I found some pouch battery cells that are 117080 that will fit in them however the delivery time could take up to 60 days I am not thrilled about this

Here is the link to them

https://www.aliexpress.us/item/32568...Cquery_from%3A

[sam_sam_sam]

The 117080 pouch battery cell will fit but you can only fit one pouch battery cell is because it only has only has a little bit over 21mm interior space and these 117080 battery are 11mm thickness so if you were to try to fit two battery cells then the enclosure case would not close properly and I do not want this situation

But one thing about 117080 versus 606080 pouch battery cells is that the 117080 is 5 amp hour and is used in car jumping battery packs and the 606080 battery cells are 2.5 amp hours and there is two of them in parallel sometimes it refers these as car jumping battery cells but not everywhere like the 117080 battery cells

[sam_sam_sam]

I bought another 8 channel battery testing machine but this came with the pouch battery clips and the ( battery testing holders built into the battery testing machine ) which will make testing 18650 battery cells much easier to do I will have to try 21700 battery cells in it as well the only thing that needs to be done is to change where screws are in now and move them down one screw hole down from where they are now and you are set to go

I mange to get this battery testing machine here to my house before the trade wars started and the price goes up or the device might be no longer available because of price increases because of tariffs I have had this battery testing machine on my wish list for a very long time and now that the landscape has changed and might not be for the better I decided to take the plunge and get it before I really can not afford it anymore

[sam_sam_sam]

Well I tried the pouch battery testing clips they are the best thing to use on the tabbing leads now I can test over one amp and not worry about the alligator clip getting to warm because of not having a good connection on the tabbing because I retest the pouch battery cells at a much higher current and the results were a lot better but unfortunately you can not buy them without buying the 8 channel battery tester which comes with the wires and the connectors plugs for the machine

There was only one place on AliExpress seller that had the pouch battery clips and no wires and or connectors for $22.00 each wow what a high price for these battery testing clips for pouch battery cells this is the reason I bought the second one with pouch battery clips as an option

[sam_sam_sam]

These battery cells must be taking the slowest ship to America that I have ever seen DHL keep showing that it is here in the United States but there is no movement sense March 8 2025 from AliExpress and they keep telling me that the shipping date has been updated but no it has not changed since March 8 so what is up with this crap and USPS does the last mile to your house and there website shows that they are still waiting for the item to arrive in there location and they also show no movement sense March 8 as well

In the last year shipping has gotten very slow and sometimes taking for ever to get to you

What ever you do not order anything from China when it gets close to the Chinese New Years because you will wait for a month before your order is even shipped and when it is on it way it still takes at least two weeks more before you receive it

[sam_sam_sam]

Well now it shows that it is in Orlando Florida who knows how long this journey is going to take because every part of this journey has been extremely long in it travels from China

[sam_sam_sam]

Funny thing now it showing that it is now in Jacksonville Florida and should be delivered on Monday late afternoon we will see if this is the case or not

[sam_sam_sam]

Well the pouch battery cells came in today in the mail now I have to drill holes in the tabbing to be able to hook it up to the battery tabbing controller board
There is enough room to put two 117080 pouch battery cells in this enclosure which I was hoping this would be the case
Now I have to order two more of them for the other battery operated tab welder I have two of the exact same model number and both of them use the same exact pouch battery cells

Now I also have to test each pouch battery cells individually at 10 load and see how they perform with this type of load

It turns out that the maximum space for the battery thickness is 22mm or it might be a little bit more than that this but I am not sure how to find out the exact specs size instead 21mm

10 amp hour X 2 = 20 amp hours charging at one amp if all drain down ( 3.00 volts ) would take 20 hours to charge up completely wow I do not think that I would run it down lower than 3.5 volts because of how long it would take to charge up

[sam_sam_sam]

Here is the results of the torture 10 amp load test on these two pouch battery cells the results are very good surprisingly enough for Chinese made battery cells now how long they last is a hole another story

I am only showing one results because they are so very similar in current/voltage curves that it does not make sense to post both of them unless they were very different to each other

The current/voltage curve is somewhat steep but you expect this for a load of ten amp load these pouch battery cells are not 10 amp hours as I stated above they five amp hour pouch battery cells so the total amp hour for both pouch battery pack would 10 amp hour but would still take 10 hours to charge at one amp which is acceptable if I can tab weld a fairly large battery pack I would not be disappointed at all the cost of each pouch battery cell was $10.00 each plus shipping which was not much because I had ordered two other pouch battery cells and two high current battery post for a project that I going to do very soon

I will be ordering another set of 107080 pouch battery cells for the other battery pack for the other battery operated battery tab welder so both of them will be the same capacity so can alternate from one welder to other battery tab welder so I do not have a temperature issue when building a large battery pack

The pictures are on the next page because it keeps giving an error message that I am not authorized to make this post really