Electric vehicles and consumer electronics depend on high-capacity,
highly efficient batteries, and the demand continues to rise. Critical to producing
these batteries is the successful welding of foil-to-tab joints which are often
made of dissimilar materials with dissimilar thicknesses. This process is
complicated, and the failure of a single joint will compromise an entire battery
pack.

Recent research by EWI shows that optimizing knurl design
for foil-to-tab joining has a greater impact on weld quality and repeatability
than optimizing parameters. FEA modeling can be used to refine tooling design,
thereby reducing the cost and lead time for developing the most suitable knurl
pattern.

This work is described in a paper by EWI Applications Engineer Tom Feister, Optimizing Knurl Patterns with FEA. To download the paper, simply fill out the form on this page.

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If you would like to discuss this work with the author, contact [email protected].