Paper: Knurl Design Optimization for Foil-to-Tab Welding in Lithium-ion Battery Cells

By Mitchell Matheny on Thursday, September 17th, 2015 in Papers. No Comments

EWI has developed a novel ultrasonic metal welding (UMW) knurl design which significantly improves the quality of foil-to-tab joints in lithium-ion battery cells. The new design allows multiple-layers to be joined in a single operation without pre-consolidation of the foils and without the use of buffer material or thicker sandwich foils. Recent test results show stronger welds, less foil damage, and a reduction in required energy.


Ultrasonic Metal Welding for Lithium-Ion Battery Cells

By Mitchell Matheny on Monday, September 15th, 2014 in Advanced Energy, Aerospace, Automotive, Consumer Electronics, Defense, EWI – Company, Friction Processes, Government, Ultrasonic Processes. No Comments

  The three most common metal to metal joints in a lithium-ion battery pack are foil to tab, tab to tab, and tab to bus. All three joints pose joining challenges, but of the three, welding multiple layers of foil to a tab is the most challenging. The joint is often made up of dissimilarRead more


2012 Battery Symposium | May 2-3 | Columbus, OH

By Mitchell Matheny on Wednesday, April 25th, 2012 in Advanced Automation, Advanced Energy, Automotive, Defense, Events, EWI – Company, Government, Laser Processing, Materials Engineering, NDE and Inspection, Resistance Processes/Solid-State Processes, Ultrasonic Processes. No Comments

EWI, OSUCAR, and CAR Technologies are hosting the 2012 Battery Symposium May 2-3 in Columbus, OH.  We have a great line up of key note speakers including Tien Duong from the US Department of Energy, as well as industry leaders from Ford and IHS Automotive.  This two day event is great for designers and manufacturers, andRead more