DOVETAIL CLAD® METAL FOR LITHIUM-ION BATTERY CONNECTIONS

As the market for electric vehicles (EVs) rapidly expands, so does the need for the lithium-ion batteries that enable this automotive technology. Because many lithium battery cells require joining a copper anode and aluminum cathode, the options for connecting the two dissimilar metals are limited, costly and can be unreliable in use. Working with top battery manufacturers, Materion has developed a breakthrough solution with Dovetail Clad metal. 

Our copper-to-aluminum Dovetail Clad strip is produced by joining these two dissimilar metals side-by-side in long continuous master coils. The coils can easily be stamped and formed to create bus bars and lead tabs especially fitted to lithium-ion battery packs for EVs, hybrid electric vehicles (HEVs) and plug in hybrid electric vehicles (PHEVs). Dovetail Clad material offers mechanical, electrical and thermal advantages over ultrasonic or bolted attachments and enables high-volume, low-cost laser assembly. 

Our cladding process achieves an excellent metallurgical bond by significantly reducing the cross-sectional area and thermal diffusion, creating a thin, ductile intermetallic compound. The result is a reliable copper-to-aluminum dovetail joint that matches the strength and fatigue toughness of the aluminum alloy.

BENEFITS OF DOVETAIL CLAD MATERIAL FOR BUS BARS AND LEAD TABS 

Benefits| Lowest electrical resistance Cu-Al interface results in cooler pack temperatures | Highest life-testing reliability in mechanical and fatigue strength | Smaller material dimensions allow for more compact module designs | Narrow Cu-AL joint width—4mm max—for optimal design flexibility 

For partial penetration laser welding, we can provide a thick inlay solution that selectively clads a stripe of copper aluminum up to 50% of the metal substrate thickness. Download the thick inlay product brief for more information. 

For more information on Dovetail Clad metal, download the Dovetail Clad product brief.

DOVETAIL CLAD METAL AVAILABILITY

• Aluminum Alloys: 1050, 1100, 1145
• Copper Alloys: C10200 with or without nickel or tin plating
• Thickness: 0.1 mm to 2.0 mm
• Width: Up to 115 mm

Contact Materion to learn how our copper aluminum Dovetail Clad technology can be applied to your unique battery pack design and address your assembly challenges.