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A battery cell has a foil-to-tab structure that is connected with multi-layer foils and a tab, and it is important to secure the weld quality to improve the battery performance. Ultrasonic metal welding (UMW) is widely applied as a technology suitable for battery cell welding because it provides a relative low heat input to welds owing to solid-state welding. In this study, 40 layers of 8 μm Cu foil and one layer of nickel-plated 0.2 mm Cu strip applied to a multilayered battery cell were used to evaluate the weldability of the materials for the UMW process. An experiment was conducted under four alignment conditions of a horn and an anvil to investigate the effect of the alignment on the weldability. The weld quality was classified based on the weld strength, discoloration, and failure mode of the test specimen to obtain a suitable welding range. The effect of the alignment condition on the deformation and weld shape was investigated by observing the cross-section of welds made under the four alignment conditions.

journal of welding and joining

Evaluation of Weldability based on Alignment Condition of Horns and Anvils used in Multilayered Battery Cell Welding Process in Ultrasonic Metal Welding