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<p>The metal-on-plastic foils are promising next-generation positive current collectors for lithium-ion batteries, offering enhanced battery safety and energy density. However, the unclear joining mechanisms between metal-on-plastic current collectors and tabs have hindered their practical deployment in&#xa0;lithium-ion batteries. In this study, tab welds were fabricated by ultrasonic welding two 0.1-mm-thick 1060 aluminum sheets to a PET-coated Al foil on both sides. The results reveal that the joining mechanism contradicts the traditional theory—where the plastic layer between the metal coatings is squeezed out and removed, allowing the intact metal layers on both sides to be pressed into contact by the welding teeth before metallurgical bonding occurs between the metal coatings and the metal tabs. Instead, the welding sonotrode penetrates and fractures the PET-coated Al foil beneath the sonotrode teeth. The upper and lower metal tabs then come into contact, undergo material mixing, and form metallurgical bond. Crucially, for battery functionality, current transmission between electrodes and tabs depends on the bottom region of the sonotrode gaps between teeth. It was found that within the functional area of the sonotrode gaps, the PET-coated Al foil remains largely intact. The dominant mechanism is friction-induced adhesion bonding between the Al coatings and Al tabs. These bonded interfaces establish essential conduction paths for electron transfer between electrode materials and tabs. In addition, optimizing welding energy is essential for battery manufacture: Increased welding energy was found to reduce tensile strength due to aggravated aluminum layer damage, while simultaneously enhancing peel strength through expansion of the inter-tab bonding area.</p>

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Ultrasonic Welding of Ultralight and Fire-Extinguishing Current Collectors to Aluminum Tabs for Lithium-Ion Batteries: Joining Mechanism and Joint Properties

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Qi Chen,
  • Juyong Cao,
  • Di Wu,
  • Ying Wang,
  • Fuyong Yang,
  • Min Wang,
  • Hui Du

摘要

The metal-on-plastic foils are promising next-generation positive current collectors for lithium-ion batteries, offering enhanced battery safety and energy density. However, the unclear joining mechanisms between metal-on-plastic current collectors and tabs have hindered their practical deployment in lithium-ion batteries. In this study, tab welds were fabricated by ultrasonic welding two 0.1-mm-thick 1060 aluminum sheets to a PET-coated Al foil on both sides. The results reveal that the joining mechanism contradicts the traditional theory—where the plastic layer between the metal coatings is squeezed out and removed, allowing the intact metal layers on both sides to be pressed into contact by the welding teeth before metallurgical bonding occurs between the metal coatings and the metal tabs. Instead, the welding sonotrode penetrates and fractures the PET-coated Al foil beneath the sonotrode teeth. The upper and lower metal tabs then come into contact, undergo material mixing, and form metallurgical bond. Crucially, for battery functionality, current transmission between electrodes and tabs depends on the bottom region of the sonotrode gaps between teeth. It was found that within the functional area of the sonotrode gaps, the PET-coated Al foil remains largely intact. The dominant mechanism is friction-induced adhesion bonding between the Al coatings and Al tabs. These bonded interfaces establish essential conduction paths for electron transfer between electrode materials and tabs. In addition, optimizing welding energy is essential for battery manufacture: Increased welding energy was found to reduce tensile strength due to aggravated aluminum layer damage, while simultaneously enhancing peel strength through expansion of the inter-tab bonding area.