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DOVETAIL CLAD® FOR LITHIUM-ION BATTERY CONNECTIONS


Copper Aluminum Dovetail Clad® is a breakthrough technology for joining copper and aluminum side-by-side in long continuous master coils. These coils can easily be stamped and formed to create bus bars or lead tabs, enabling high-volume, low-cost laser assembly especially fitted to automotive format lithium-ion battery packs for HEV’s, PHEV’s and EV’s.

Our patented cladding process achieves an excellent metallurgical bond by combining extreme reductions in cross-sectional area and thermal diffusion to create a controlled formation of a thin, ductile intermetallic compound resulting in a robust copper-aluminum dovetail joint which matches the strength and fatigue toughness of the aluminum alloy.



 

BUS BAR AND LEAD TAB MATERIALS FOR COOLER, SMALLER LITHIUM-ION BATTERY PACKS

Dovetail Clad battery bus bar and lead tab materials are superior in mechanical, electrical and thermal performance over ultrasonic or bolted attachments, immediately benefitting your lithium-ion battery pack design, assembly and product lifecycle:

Dovetail Clad Bus Bars facilitate laser welding in lithium-ion battery packs
  • Lowest electrical resistance Cu-Al interface results cooler pack temperatures
  • Highest life-testing reliability in mechanical and fatigue strength
  • Low height allows for more compact module designs
  • Narrow Cu-Al joint width - 4mm max - for optimal design flexibility
     
Replace anode or cathode with Dovetail Clad Lead Tabs to simplify lithium-ion battery pack bussing

PRODUCT AVAILABILITY

  • Aluminum Alloys: 1050, 1100, 1145
  • Copper Alloys: C10200 with or without Nickel or Tin plating
  • Thickness: 0.1mm to 2.0mm
  • Width: Up to 165mm

Based on nearly 50 years of expertise in cladding aluminum to copper for high-reliability automotive lead frame applications, Materion Technical Materials has taken their state-of-the-art metal cladding technology to a new level to meet the challenges facing every lithium-ion battery cell and pack designer: how to join copper and aluminum in your battery pack.

Contact Materion Technical Materials to learn how our Copper Aluminum Dovetail Clad® technology can be applied to your unique battery pack design and assembly challenges.