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DOVETAIL CLAD® METAL FOR LITHIUM-ION BATTERY CONNECTIONS


Our copper-to-aluminum Dovetail Clad® strip is produced using a breakthrough patented cladding technology that joins these two dissimilar metals side-by-side in long continuous master coils. These coils can easily be stamped and formed to create bus bars and lead tabs especially fitted to automotive format lithium-ion battery packs for hybrid electrical vehicles (HEVs), plug in hybrid electric vehicles (PHEVs) and electric vehicles (EVs). Dovetail Clad material offers mechanical, electrical and thermal advantages, and it 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 copper-to-aluminum dovetail joint that 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:

  • 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

Clad Bus Bars

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Dovetail Clad Bus Bars facilitate
laser welding of like metals.

Clad Lead Tabs

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Replace Anode or Cathode with
Dovetail Clad metal to simplify 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 has taken 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 to learn how our copper aluminum dovetail clad® technology can be applied to your unique battery pack design and assembly challenges.