Sacrificial Layer to Facilitate Welding of Thin Foils

Cost-effective method to prevent damaged electrodes when welding thin foils.

The Need

Manufacturing of automotive lithium-ion batteries and battery packs is attracting growing attention with the driving demands of electric vehicles. During battery assembly, multi-layers of metal films, functioning as anodes, cathodes, or bus-bars are welded together. Achieving satisfying weld quality for the desired power and capacity requirement at low manufacturing cost is critical for a reliable battery pack and electric vehicle performance. Resistance spot welding is often used to weld a plurality of battery foils using pressure and heat from an electric current to weld two or more metal sheets together. The electric current is applied to the weld area via an electrode. The current method of welding the plurality of battery foils is challenging. It can often damage the electrode deteriorating the life of the electrode, increasing electrode cost, and slowing the production rate.

The Technology

The technology disposes a replaceable electrically conducting interlayer comprised of graphene, graphite, carbon-nanotube paper; carbon nanotube-carbon black paper; or a combination thereof onto the electrode at the opening to the electrically insulating sheath. The electrically conducting interlayer is designed to allow the elecrodes to transmit or receive electrical currents while preventing adhesion of the electrode to the battery foil or battery tab during the welding process.

Commercial Applications

This invention can be a cost-effective method to weld thin foils in battery manufacturing.


This technology drastically decreases damaged electrodes when welding foils, increases production rate and decreases electrode cost.


  • US 17/668,708
  • Non-exclusive licensing rights available

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