Joining Characteristics of 60-Layered Cu Foil Stack Using Linear Vibration Ultrasonic Welding
Seong Min Hong, Bum-Su Go, Hee-Seon Bang
TL;DR
This study explores how to best weld 60 layers of copper foil for lithium-ion batteries using ultrasonic welding, focusing on optimizing parameters to ensure strong, reliable joints.
Contribution
The study identifies optimal welding energy and parameters for joining 60-layered copper foil stacks without surface defects.
Findings
Optimal welding energy (500–900 J) produced well-formed joints without surface cracks or tearing.
Excessive welding energy (>900 J) caused material thinning and interfacial failure.
The maximum T-peel peak load of 138.7 N was achieved under specific amplitude, time, and pressure conditions.
Abstract
This study investigates the joint characteristics of a 60-layered copper foil stack using linear vibration ultrasonic welding for lithium-ion pouch cell applications. With increasing demand for high-capacity electric vehicle batteries, ensuring the reliability of multilayer electrode joints is essential. Experiments were conducted by varying vibrational amplitude, welding time, and clamping pressure. Weld quality was analyzed based on indentation profiles, joint strength, and failure modes. Results revealed that optimal welding energy (500–900 J) produced well-formed joints without surface cracks or tearing. Excessive welding energy (>900 J) led to material thinning and interfacial failure. The maximum T-peel peak load of 138.7 N was obtained at the 30th joining interface under 25 µm amplitude, 0.8 s welding time, and 1.5 bar clamping pressure. Interface-dependent optimum conditions…
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Taxonomy
TopicsAdvanced Welding Techniques Analysis · Welding Techniques and Residual Stresses · Electronic Packaging and Soldering Technologies