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Joining Characteristics of 60-Layered Cu Foil Stack Using Linear Vibration Ultrasonic Welding
Seong Min Hong1, Bum-Su Go2, Hee-Seon Bang3
1Joining and Welding Research Institute, The University of Osaka, Osaka 567-0047, Japan.
Materials (Basel, Switzerland)
|February 27, 2026
Summary
This study optimized ultrasonic welding for 60-layer copper foil stacks in lithium-ion batteries. Optimal energy ensures strong, reliable multilayer electrode joints essential for electric vehicle battery performance.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Electrochemistry
Background:
- Growing demand for high-capacity electric vehicle batteries necessitates reliable multilayer electrode joints.
- Ensuring the integrity of copper foil stacks is critical for lithium-ion pouch cell performance and safety.
Purpose of the Study:
- To investigate the joint characteristics of a 60-layered copper foil stack using linear vibration ultrasonic welding.
- To determine the optimal welding parameters for high-quality multilayer foil joints in battery manufacturing.
Main Methods:
- Experiments varied vibrational amplitude, welding time, and clamping pressure.
- Weld quality assessed via indentation profiles, joint strength (T-peel test), and failure mode analysis.
- Analyzed interface-dependent optimum conditions within the 60-layer stack.
Main Results:
- Optimal welding energy (500-900 J) yielded well-formed joints without defects.
- Excessive energy (>900 J) caused material thinning and interfacial failure.
- Maximum T-peel load of 138.7 N achieved at the 30th interface with specific parameters (25 µm amplitude, 0.8 s, 1.5 bar).
Conclusions:
- Ultrasonic welding parameters significantly influence multilayer copper foil joint quality.
- Interface-dependent optimal conditions exist due to thickness-direction variations.
- Findings provide crucial guidelines for optimizing welding in battery manufacturing for enhanced reliability.
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