Custom Pouch-Cell Tab Lead Manufacturing

Problem solved

Pouch cell tab leads must provide a hermetically sealed electrical feedthrough between the cell interior (organic electrolyte) and external circuit, while withstanding the cell assembly heat-seal process and long-term exposure to electrolyte. Improper tab lead design causes electrolyte leakage, cell degradation, and fire risk. Standard off-the-shelf tab leads do not accommodate the wide variety of cell capacities, form factors, and current ratings required by custom pouch cell projects.

Application contexts

• custom pouch cell prototype and production runs
• mid-to-small volume Li-ion battery manufacturing
• specialty pouch cells for medical, industrial, and consumer devices
• battery R&D labs requiring flexible tab lead sourcing

Technical principle

A flat-rolled metal conductor (aluminum for cathode, nickel-plated copper or nickel for anode) is partially laminated on both sides with a multi-layer polyolefin sealant film. The sealant film fuses with the aluminum laminate pouch film during the cell heat-seal process, creating an electrolyte-tight barrier. Key parameters: conductor cross-section for current rating, sealant film composition for electrolyte resistance, and seal width for mechanical integrity.

Typical use cases

• Prototype pouch cell tab leads for a university or startup battery developer needing 100-500 custom units
• Medical device pouch cell requiring biocompatible sealant materials and tight dimensional tolerances
• Industrial-grade large-format pouch cell requiring high-current nickel-plated copper tab leads