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Ultrasonic welding is widely applied in battery manufacturing, covering multiple key processes from cells to modules:
◆ Tab Welding: Connect cell tabs (nickel, aluminum, copper) to busbars or external circuits, a core process in battery production.
◆ Multi-layer Tab Welding: Achieve high-quality, damage-free bonding between multiple ultra-thin metal foils and tabs.
◆ Busbar Welding: Precisely weld busbars onto cell tabs to realize series and parallel connection of cells.
◆ Battery Housing Sealing: Tightly weld the top cover and bottom housing to form a sealed cavity.
◆ Applicable battery types: cylindrical batteries, prismatic batteries, pouch batteries, solid-state and semi-solid-state batteries.
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Advantages | Explanation |
Almost the only viable solution | For welding multilayer ultra-thin metal foils, ultrasonic is almost the only welding solution that can be scaled up |
High precision and consistency | Welding precision can reach the micron level, with a tab welding yield rate of 99.8% |
Low temperature efficiency is high | Avoid thermal damage, achieve fast welding speed, and high production efficiency |
Low internal resistance | The battery has lower internal resistance, generates less heat, and has higher charge/discharge efficiency |
Compatible with distinct metals | Supports various dissimilar metal combinations such as copper-aluminum and copper-nickel |
Ultrasonic welding complements laser welding in power battery production—ultrasonic welding is mainly used for multi-layer tab welding in intermediate processes, while laser welding is used for flexible connections and top cover welding. Each has its own responsibilities, working together to ensure the quality of the battery's electrical connections.