To solder lithium batteries properly, you need a very high-power soldering iron. This may seem paradoxical at first, but a high-powered soldering iron is able to perform soldering operations much quicker, resulting in less overall heat being imparted into the cells from the hot solder.
Step 1: Disassemble the battery pack, if you need to, so you can get to the cells. Step 2: Clean the cell ends so that when you solder, you will be able to make a secure, strong connection. Step 3: Turn on the soldering iron and allow it to heat up all the way.
Try to use a thicker soldering iron tip as it transfer heat more effectively. Quickly tin both terminals (apply a small blob of solder to each battery terminal). The goal is to get in and out fast — ideally in under a couple of seconds. If the iron is in contact with the battery for too long, heat will build up and it becomes risky.
Soldering Li-ion batteries such as 18650 or 21700 cells can be risky. If overheated, these cells can catch fire, or even explode. That’s why spot welding is always the preferred and safest method for making Li-ion packs. However, if you don’t have access to a spot welder, soldering is still possible with care and the right tools.
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Heat the soldering iron to 450 C (842 F). Less might also work, but this is the temperature that I used. Put some solder on your iron, then put the soldering iron on the cell, …
Learn safe techniques for Soldering Li-Ion cells. Step-by-step tips, benefits vs spot welding, and advice for building reliable battery packs.
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