Battery supporting materials
4mm Wide Aluminum Battery Tabs for Pouch Cell Current Collection
Item Number : CL35
Price varies based on specs and customizations
- Material & Purity
- Aluminum 99.99%
- Dimensions (W × L × T)
- 4mm × 48mm × 0.10mm
- Max Current Capacity
- 3A
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Product Overview
This high-purity 4mm wide aluminum battery tab serves as a critical terminal lead component designed specifically for pouch cell fabrication, lithium-ion battery research, and advanced energy storage prototyping. Manufactured from certified 99.99% high-purity aluminum, the conductive lead provides an ultra-low-resistance current pathway between internal cathode current collectors and external testing circuits. Its calibrated dimensions and uniform cross-section minimize electrical bottlenecks while ensuring consistent mechanical performance during cell cycling.
Engineered to meet the stringent demands of modern electrochemical laboratories, pilot lines, and battery manufacturing facilities, this aluminum lead is optimized for pouch cell cathode termination, supercapacitor development, and specialized solid-state cell builds. The material's refined surface chemistry and dimensional consistency facilitate flawless ultrasonic metal welding with aluminum foil stacks, ensuring low contact impedance and high mechanical shear strength across all testing regimes.
Designed for extreme operational stability and reliability under aggressive cycling conditions, the tab withstands high continuous current loads up to 3A without localized thermal runaway or structural degradation. Its exceptional chemical resistance protects against electrolyte corrosion and oxidation, making this component a dependable, high-yield choice for demanding research environments and commercial qualification workflows.
Key Features
- Ultra-High Purity 99.99% Aluminum Substrate: Fabricated from premium refined aluminum to maximize electrical conductivity, reduce internal cell resistance, and eliminate trace contaminant-induced parasitic reactions during long-term cycling.
- Optimized 4mm Conductive Profile: Precision-slit 4mm width provides the ideal balance between surface contact area for ultrasonic welding and compact packaging efficiency in standard pouch cell envelopes.
- Calibrated 0.10mm Gauge Thickness: Maintains an ultra-thin cross-sectional profile that integrates seamlessly into pouch laminate seals, preventing micro-channel leaks while delivering high mechanical flexibility during terminal bending.
- Robust 3A Continuous Current Rating: Engineered to support continuous current loads up to 3A with minimal resistive heating, ensuring thermal stability across standard charging and moderate discharge rate evaluations.
- Ultra-Lightweight 60mg Formulation: Delivers an exceptionally low unit weight of approximately 60mg per piece, preserving gravimetric energy density benchmarks in precision pouch cell prototyping.
- Superior Ultrasonic Weldability: Smooth, uniform surface finish facilitates rapid acoustic energy transfer during ultrasonic wire and tab welding, creating low-impedance, high-tensile metallurgical bonds with positive foil stacks.
- High Corrosion and Electrolyte Resistance: Pure aluminum metallurgical composition exhibits natural passivating oxide formation that resists degradation from common organic carbonate solvents and lithium hexafluorophosphate salts.
- Full Dimensional Customization: Available in a standard 48mm length with extensive customization options for length, width, and surface treatment to suit unique cell geometry and fixture constraints.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Lithium-ion Pouch Cell Cathode Lead | Serves as the primary positive terminal conductor welded directly to multi-layered aluminum current collector foils. | Ensures ultra-low contact resistance and prevents localized heating at high charge and discharge rates. |
| Solid-State Battery R&D | Integrates into prototype solid-state pouch cells operating with advanced solid electrolytes and high-voltage cathodes. | High-purity 99.99% aluminum prevents trace metal contamination and interface breakdown under high operating voltages. |
| Supercapacitor Current Extraction | Connects internal electrode stacks to external power terminals in high-power electric double-layer capacitors (EDLCs). | Rapid electron transport properties support swift discharge cycles and minimize internal equivalent series resistance (ESR). |
| Sodium-ion Cell Prototyping | Utilized as the positive terminal lead for emerging sodium-ion chemistry pouch cells utilizing aluminum cathode substrates. | Chemical compatibility with emerging non-aqueous electrolytes ensures structural stability without dissolution. |
| Electrochemical Impedance Spectroscopy | Provides a standardized, highly reproducible electrical connection for precision impedance and rate-capability diagnostics. | Eliminates artifact resistance and noise in frequency response data, boosting academic and R&D data repeatability. |
| Battery Pilot Line Pre-Production | Applied in semi-automated pouch cell assembly lines for pilot-scale cell qualification and process optimization. | Uniform dimensional tolerances facilitate repeatable robotic pick-and-place and ultrasonic welding parameters. |
Technical Specifications
| Parameter | Specification (Item No: CL35) |
|---|---|
| Substrate Material | High-Purity Aluminum (Al) |
| Material Purity | 99.99% |
| Standard Width | 4.0 mm (Customizable upon request) |
| Standard Length | 48.0 mm (Customizable upon request) |
| Material Thickness | 0.10 mm (100 µm) |
| Maximum Current Carrying Capacity | 3.0 A |
| Net Weight per Piece | Approx. 60 mg (0.060 g) |
| Electrical Conductivity | High-conductivity grade (IACS compliant) |
| Terminal Polarity Compatibility | Positive Terminal (Cathode / Current Collector) |
| Recommended Bonding Technique | Ultrasonic Metal Welding (Al-to-Al foil) |
| Sealing Compatibility | Suitable for thermal sealing with polymer pouch laminate films |
| Customization Options | Extended length, tailored width, pre-applied sealant film options |
Why Choose This Product
- Uncompromising Material Purity: Every batch is processed from 99.99% pure aluminum to eliminate foreign metallic inclusions, preventing internal micro-shorts and preserving electrochemical integrity across thousands of cycles.
- Precision Slitting and Edge Finishing: Tight dimensional tolerances and burr-free edge quality prevent puncture damage to delicate pouch cell barrier films, ensuring hermetic seal integrity during vacuum sealing.
- Flawless Weld Consistency: Engineered specifically for ultrasonic bonding, the tab provides uniform acoustic impedance that yields reproducible, high-strength welds with minimal horn wear and zero foil tearing.
- Tailored Engineering Support: Beyond standard dimensions, customized lengths, widths, and pre-packaged quantities are available to match exact pilot line tooling, laboratory jigs, and high-throughput automation requirements.
Contact our technical sales team today to request a quote, order evaluation samples, or discuss custom dimensional specifications for your pouch cell assembly workflow.
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