Are cells in battery sticks generally welded together?

[JohnnyB]

I have 2 store bought sticks with 5, 1/2 Ds and I was wondering if the individual cells are usually welded together or if they are just held together by the plastic wrapping.

I don't have an old one to tear apart to see.

Thanks

 

[Manzerick]

I believe most are just shrink wraped

 

[Bullzeyebill]

I believe most are just shrink wraped

The 5 1/2D's were most likely 1/2D that had tabs on the + and - ends and were welded together, then shrink wrapped together as one battery pack. Streamlight packs and Maglight packs, OEM and after market, are usually made this way, never just shrink wrapped together without good bonding between cells. Some people will solder the batteries together using tabs.

Bill

 

[LuxLuthor]

Depends on who made them. Using welded tabs is the easiest and least damaging to the cells. Using a quick, high heat solder connection with hammerhead tip is next best for reliable connection. Just shrinkwrapping ignores the development over time of oxidation/carbon plating on the outside surfaces reducing contact.

If you have used FiveMega and other brands of battery holders for any length of time, you will see a coating develop that reduces the connection reliability. Doing a light sanding with fine automotive 600 grit paper, or even a pencil eraser removes the oxidation and exposes bare metal again.

 

[JohnnyB]

Thanks very much guys!