Multilayer laminated composite material

Abstract

A metal laminate composite comprising a first layer containing a copper-containing compound, a second layer selected from steel or stainless steel, and a third layer selected from copper or a copper alloy. The second layer constitutes 7 vol% to 25 vol% of the metal laminate composite. In some cases, the composite exhibits a yield strength exceeding 80 MPa.

Description

[Technical Field]

[0001] Cross-reference of related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 505,120, filed on 31 May 2023, entitled “Multilayer Laminate Composite,” the disclosure of which is incorporated herein by reference in its entirety.

[0002]

[0002] This disclosure provides laminate composite materials having multiple layers of metal or metal alloy. In particular, this disclosure relates to multilayer laminate composite materials including a surface layer containing a copper compound. [Background technology]

[0003]

[0003] Several multilayer metal laminate materials are known. These conventional laminate materials are often suitable for use as connectors in battery packs or in resistance welding applications.

[0004]

[0004] For example, U.S. Patent No. 10,707,472 discloses a multilayer metal laminate, in which a multilayer laminate composite material includes a first metal layer having good solderability, e.g., commercially available nickel or nickel alloy; a second metal layer having good resistance welding properties, e.g., commercially available steel or stainless steel; a third metal layer having low electrical resistivity, e.g., commercially available copper and copper alloy; a fourth metal layer having good resistance welding properties, e.g., commercially available steel or stainless steel; and a fifth metal layer having good solderability, e.g., commercially available nickel or nickel alloy.

[0005]

[0005] U.S. Patent Application No. 2010 / 0178559 discloses a nickel-copper clad tab for the negative electrode of a rechargeable battery and a method for manufacturing the same. A system and method for constructing a tab in a rechargeable battery may include a current collector comprising one or more current collector foils and one or more tabs connected to the current collector foils for transporting the generated current away from the current collector. The tabs may be configured to draw a larger capacity from the battery electrodes so that the resulting battery exhibits higher performance. The tabs may be configured such that the negative electrode tab is a clad having nickel and copper layers. [Overview of the project] [Problems that the invention aims to solve]

[0006]

[0006] Even considering known references regarding multilayer metal laminates, there is a need for a multilayer laminate that shows improved soldering / welding performance while simultaneously achieving improved corrosion resistance. [Means for solving the problem]

[0007]

[0007] The present disclosure provides a metal laminate composite comprising: a first layer containing a copper-containing compound; a second layer selected from steel or stainless steel; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound. The composite exhibits conductivity in the range of 40%IACS to 82%IACS as determined by ASTM E1004, while the first layer of the multilayer laminate has conductivity of less than 10%IACS. The metal laminate composite further exhibits excellent corrosion resistance as determined by SAE / USCAR25.6.2 and ASTMB117.

[0008]

[0008] The copper-containing compound may be copper, a copper alloy such as a copper-nickel alloy or a copper-nickel-tin alloy, or a combination thereof. More specifically, in the case of a copper alloy such as a copper-nickel alloy, copper is present in an amount ranging from 60 wt.% to 95 wt.%, and nickel is present in an amount ranging from 5 wt.% to 40 wt.%, for example, an amount exceeding 5 wt.% and less than 35 wt.%.

[0009]

[0009] In some embodiments, the first layer constitutes 0.9 vol.% to 10 vol.% of the laminate composite; the second layer constitutes 7 vol.% to 25 vol.% of the laminate composite; the third layer constitutes 40 vol.% to 80 vol.% of the laminate composite; the fourth layer constitutes 7 vol.% to 25 vol.% of the laminate composite; and / or the fifth layer constitutes 0.9 vol.% to 10 vol.% of the laminate composite. In these embodiments, the annealed metal laminate composite exhibits a tensile modulus in the range of 120 GPa to 180 MPa, a yield strength exceeding 80 MPa, and / or a flexural modulus exceeding 135 GPa.

[0010]

[0010] In some embodiments, the first layer constitutes 0.7 vol.% to 1.4 vol.% of the laminate composite; the second layer constitutes 7 vol.% to 25 vol.% of the laminate composite; the third layer constitutes 40 vol.% to 80 vol.% of the laminate composite; the fourth layer constitutes 7 vol.% to 25 vol.% of the laminate composite; and / or the fifth layer constitutes 0.7 vol.% to 1.4 vol.% of the laminate composite, and the laminate composite exhibits a flexural strength exceeding 62 MPa.

[0011]

[0011] The metal laminate composite may be used as a connector tab for a lithium-ion battery pack.

Brief Description of the Drawings

[0012] [Figure 1]

[0012] A figure showing the multilayer laminate composite disclosed herein.

Modes for Carrying Out the Invention

[0013] Introduction

[0013] As described above, conventional laminate materials often employ nickel or nickel alloys, etc. as the skin layer. These metals / alloys are known to be expensive and in some cases toxic. These materials may also have high thermal conductivity, which can have an adverse effect and easily spread heat over the entire surface. Since the heat is dispersed over the entire surface area, this can limit the performance of effectively performing resistance welding. Furthermore, it has been found that conventional laminate materials have problems not only with potential toxicity but also with corrosion resistance due to metallurgical reasons in their skin layer. Also, in certain applications such as the connector tabs of battery packs, especially when used in high-power applications, these materials can cause a decrease in battery performance and safety due to resistive heating.

[0014]

[0014] The use of a low-thermal-conductivity metal (as the skin layer) and a specific metal in the second layer, both at specific volume percentages, has been found to result in a synergistic combination of performance, for example, with better yield strength performance, and in some cases cost-benefit, an improvement in the performance of (resistance) welding and / or soldering, and a reduction in toxicity.

[0015]

[0015] It has been shown that the selected layers provide surprising advantages when present at specific volume percentages. Specifically, when the second layer is present in a volume less than 7 vol% of the entire laminate composite, the yield strength is impaired even if the solderability is maintained. The disclosed percentages contribute to the combination of the above advantages, for example, solderability and yield strength.

[0016]

[0016] The inventors have now found that certain (non-nickel) metals and / or metal alloys, such as copper or copper alloys, are remarkably effective when used, for example, as a skin layer in multilayer laminate materials. In several cases, the use of metals or alloys with low thermal conductivity results in multilayer laminates that exhibit a synergistic combination of performance and chemical / metallurgical properties. For example, as described above, multilayer laminate materials can exhibit improved performance in welding and / or soldering, such as resistance welding, as well as unexpected corrosion resistance. While not bound by theory, it is assumed that, in use, metals with low thermal conductivity localize heat (from welding or soldering operations) more. That is, metals with low thermal conductivity concentrate heat in precisely defined areas, which leads to improved weldability. In contrast, conventional laminates dissipate heat much more easily, which has a very negative impact on welding or soldering operations. Furthermore, corrosion resistance is improved due to the metallurgical reasons of the surface layer (compared to conventional nickel surface layers).

[0017]

[0017] Furthermore, when the above-mentioned copper or copper alloy layer is used, it has been found that the resulting laminate shows a remarkable improvement in yield strength compared to conventional laminates, for example, those using nickel or a nickel alloy in the surface layer.

[0018]

[0018] Therefore, the multilayer laminate composites disclosed herein offer significant advantages in terms of cost, yield strength, weldability, solderability, and corrosion resistance, while simultaneously continuing to exhibit the desirable properties of known materials.

[0019] multilayer composite

[0019] This disclosure relates to a multilayer laminate composite material comprising a first layer (skin layer), a second layer (weldability layer), and a third layer (conductive layer). In some cases, the multilayer laminate composite material comprises a first metal layer comprising copper or a copper alloy, a second metal layer comprising steel or stainless steel, and a third metal layer comprising copper or a copper alloy. In some embodiments, an optional fourth metal layer comprising steel or stainless steel, and / or an optional fifth metal layer comprising copper or a copper alloy are employed. In some embodiments, the first metal layer constitutes more than 0.9 vol% of the multilayer laminate composite material, and the second metal layer constitutes more than 7 vol% of the multilayer laminate composite material. In some embodiments, the first metal layer constitutes 0.7 vol% to 1.4 vol% of the multilayer laminate composite material, and the second metal layer constitutes more than 7 vol% of the multilayer laminate composite material.

[0020]

[0020] Multilayer laminated composites offer advantages in terms of improved weld and / or soldering performance. For example, multilayer composites require lower weld force and shorter welding times than conventional materials, and at the same time can withstand higher peak welding currents.

[0021]

[0021] In some cases, multilayer composites may exhibit improved electrical conductivity (in addition to weld / soldering performance), for example, conductivity in the range of 40% to 82% IACS as measured by ASTM E1004, e.g., 41% to 81%, 42% to 80%, 43% to 79%, 44% to 78%, 45% to 77%, 46% to 76%, 47% to 75%, 48% to 74%, 49% to 73%, 50% to 72%, 51% to 71%, 52% to 70%, 53% to 69%, 54% to 68%, 55% to 67%, 56% to 66%, 57% to 65%, 58% to 64%, 59% to 63%, or conductivity in the range of 60% to 62%. Regarding the upper limit, the conductivity of the multilayer metal laminate composite may be less than 82%, for example, less than 81%, less than 80%, less than 79%, less than 78%, less than 77%, less than 76%, less than 75%, less than 74%, less than 73%, less than 72%, less than 71%, less than 70%, less than 69%, less than 68%, less than 67%, less than 66%, less than 65%, less than 64%, less than 63%, less than 62%, or less than 61%. Regarding the lower limit, the conductivity of the multilayer metal laminate composite material may be greater than 40%, greater than 41%, greater than 42%, greater than 43%, greater than 44%, greater than 45%, greater than 46%, greater than 47%, greater than 48%, greater than 49%, greater than 50%, greater than 51%, greater than 52%, greater than 53%, greater than 54%, greater than 55%, greater than 56%, greater than 57%, greater than 58%, greater than 59%, or greater than 60%.

[0022]

[0022] Multilayer composites may exhibit superior corrosion resistance compared to conventional materials. Corrosion resistance may be measured, for example, by SAE / USCAR2 5.6.2 and ASTM B117. Furthermore, multilayer composites may exhibit excellent discoloration resistance. Other performance characteristics will be discussed in detail below.

[0023]

[0023] The layers may be configured together to form a multilayer composite material, for example, they may be joined to each other. In some cases, the first layer and an optional fifth layer may be configured as a skin layer, for example as an outer layer, and the second layer and an optional fourth layer may be configured as inner layers, and may be adjacent to the first and optional fifth layers, respectively. The third layer may be sandwiched between the second layer and the optional fourth layer.

[0024]

[0024] The layers may be constructed using known techniques, which may be diverse. Exemplary methods include roll bonding, cold roll bonding, hot roll bonding, or circumferential welding of ingots, billets, or slabs (with optional subsequent cold-hot rolling). Other techniques include adhesive bonding, diffusion bonding, cold roll bonding, explosive bonding, electrodeposition, or flame spraying of one layer to a substrate of another layer.

[0025] First layer

[0025] The first layer comprises copper and / or copper alloys or other copper-containing compounds. The use of these metals in the skin layer advantageously improves welding and / or soldering performance (compared to conventional laminates that utilize a nickel skin layer). Conventional laminates require nickel or a nickel alloy as the skin layer, which contributes to insufficient performance (see discussion above). Conventional copper skin layers exhibit electrical conductivity values ​​exceeding 100% IACS, and conventional nickel skin layers may exhibit electrical conductivity values ​​of 18% IACS. Advantageously, the first layer disclosed herein may exhibit lower electrical conductivity values ​​as measured by ASTM E1004, e.g., less than 15% IACS; for example, less than 14% IACS, less than 13% IACS, less than 12% IACS, less than 11% IACS, less than 10% IACS, less than 9% IACS, less than 8% IACS, less than 7% IACS, less than 6% IACS, or less than 5% IACS. When used, the use of the disclosed first layer, for example, a layer of copper-containing compounds, contributes to the synergistic combination of the above-mentioned performances. The second and third layers (as well as optional fourth and fifth layers) will be discussed in detail below.

[0026]

[0026] The first layer may contain copper or a copper alloy. If the first layer contains a copper alloy, the copper alloy may contain 50 wt.% to 95 wt.% of copper, for example 51 wt.% to 95 wt.%, 55 wt.% to 90 wt.%, 60 wt.% to 85 wt.%, 65 wt.% to 80 wt.%, or 70 wt.% to 75 wt.% of copper. With respect to the upper limit, the alloy may contain less than 95 wt.% of copper, for example less than 90 wt.%, less than 85 wt.%, or less than 80 wt.% of copper. Regarding the lower limit, the copper alloy may contain more than 50 wt.% of copper, for example, more than 51 wt.%, more than 55 wt.%, more than 60 wt.%, more than 65 wt.%, more than 70 wt.%, or more than 75 wt.%. The copper alloy may also contain a second metal, such as nickel, which will constitute the remainder of the alloy's composition.

[0027]

[0027] In some cases, the copper alloy may be composed of a copper-nickel alloy, but is not limited to cupronickel alloys, nickel-silver alloys, and / or copper-nickel-tin alloys. Suitable commercially available copper alloys include, for example, C70600, C71500, C71640, C702500, C702600, C72500, C72900, C73500, C75200, C76200, and C77000.

[0028]

[0028] The first layer may constitute 0.9 vol% to 10 vol% of the entire laminate composite material, for example, 1.0 vol% to 9 vol%, 1.1 vol% to 8 vol%, 1.2 vol% to 7 vol%, 1.3 vol% to 6 vol%, 1.4 vol% to 5 vol%, 1.5 vol% to 4 vol%, 1.6 vol% to 3 vol%, 1.7 vol% to 2 vol%, or 1.8 vol% to 1.9 vol%. As an upper limit, the first layer may constitute less than 10 vol% of the entire laminate composite material, for example, less than 9 vol%, less than 8 vol%, less than 7 vol%, less than 6 vol%, less than 5 vol%, less than 4 vol%, less than 3 vol%, less than 2 vol%, or less than 1.9 vol%. Regarding the lower limit, the first layer may constitute more than 0.9 vol% of the total laminate composite material, for example, more than 1.0 vol%, more than 1.1 vol%, more than 1.2 vol%, more than 1.3 vol%, more than 1.4 vol%, more than 1.5 vol%, more than 1.6 vol%, more than 1.7 vol%, or more than 1.8 vol%.

[0029]

[0029] Alternatively, the first layer may constitute 0.7 vol% to 1.4 vol% of the entire laminate composite, for example, 0.8 vol% to 1.3 vol%, 0.9 vol% to 1.2 vol%, or 1.0 vol% to 1.1 vol%. With respect to the upper limit, the first layer may constitute less than 1.4 vol% of the entire laminate composite, for example, less than 1.3 vol%, less than 1.2 vol%, or less than 1.1 vol%. With respect to the lower limit, the first layer may constitute more than 0.7 vol%, for example, more than 0.8 vol%, more than 0.9 vol%, or more than 1.0 vol%.

[0030]

[0030] In some cases, the first layer contributes to improved weldability. Suitability for welding can be determined, for example, by the tendency for cracks to form at the joint, the thermal expansion of the material, and the thermal conductivity of the material. The overall weldability of the material is evaluated herein on a scale from 1 to 5, where 1 indicates poor weldability and 5 indicates excellent weldability. Alternatively, weldability may be measured by the tensile strength of the joint.

[0031]

[0031] When referring to a copper-nickel alloy, the copper-nickel alloy or copper-nickel-tin alloy contains the above-mentioned amount of copper and an amount of nickel in the range of 5 wt.% to 40 wt.%, for example, 6 wt.% to 39 wt.%, 7 wt.% to 38 wt.%, 8 wt.% to 37 wt.%, 9 wt.% to 36 wt.%, 10 wt.% to 35 wt.%, 11 wt.% to 34 wt.%, 12 wt.%. It contains nickel in amounts ranging from %~33 wt.%, 13 wt.%~32 wt.%, 14 wt.%~31 wt.%, 15 wt.%~30 wt.%, 16 wt.%~29 wt.%, 17 wt.%~28 wt.%, 18 wt.%~27 wt.%, 19 wt.%~26 wt.%, 20 wt.%~25 wt.%, 21 wt.%~24 wt.%, or 22 wt.%~23 wt.%. Regarding the upper limit, the amount of nickel may be less than 40 wt.%, for example, less than 39 wt.%, less than 38 wt.%, less than 37 wt.%, less than 36 wt.%, less than 35 wt.%, less than 34 wt.%, less than 33 wt.%, less than 32 wt.%, less than 31 wt.%, less than 30 wt.%, less than 29 wt.%, less than 28 wt.%, less than 27 wt.%, less than 26 wt.%, less than 25 wt.%, less than 24 wt.%, or less than 23 wt.%. Regarding the lower limit, the amount of nickel may be greater than 5 wt.%, for example, greater than 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 11 wt.%, 12 wt.%, 13 wt.%, 15 wt.%, 16 wt.%, 17 wt.%, 18 wt.%, 19 wt.%, 20 wt.%, 21 wt.%, or 22 wt.%.

[0032]

[0032] When referring to a copper-nickel-tin alloy, the copper-nickel-tin alloy contains less than 10 wt.% of tin, for example less than 9 wt.%, less than 8 wt.%, less than 7 wt.%, less than 6 wt.%, less than 5 wt.%, less than 4 wt.%, less than 3 wt.%, less than 2 wt.%, or less than 1 wt.%.

[0033]

[0033] The copper-nickel alloy or copper-nickel-tin alloy contains less than 2.0 wt.% of iron, for example less than 1.9 wt.%, less than 1.8 wt.%, less than 1.7 wt.%, less than 1.6 wt.%, less than 1.5 wt.%, less than 1.4 wt.%, less than 1.3 wt.%, less than 1.2 wt.%, less than 1.1 wt.%, less than 1.0 wt.%, less than 0.9 wt.%, less than 0.8 wt.% It may further contain amounts of iron less than 0.7 wt.%, less than 0.6 wt.%, less than 0.5 wt.%, less than 0.4 wt.%, less than 0.3 wt.%, less than 0.2 wt.%, less than 0.1 wt.%, less than 900 ppm, less than 800 ppm, less than 700 ppm, less than 600 ppm, less than 500 ppm, less than 400 ppm, less than 300 ppm, less than 200 ppm, or less than 100 ppm.

[0034]

[0034] The copper-nickel alloy or copper-nickel-tin alloy may further contain zinc in amounts ranging from 1 wt.% to 40 wt.%, for example, in amounts ranging from 5 wt.% to 35 wt.%, 10 wt.% to 30 wt.%, or 15 wt.% to 25 wt.%. With respect to the upper limit, the amount of zinc may be less than 40 wt.%, for example, less than 35 wt.%, less than 30 wt.%, less than 25 wt.%, or less than 20 wt.%. With respect to the lower limit, the amount of zinc may be greater than 1 wt.%, for example, greater than 5 wt.%, greater than 10 wt.%, or greater than 15 wt.%.

[0035]

[0035] The copper-nickel alloy or copper-nickel-tin alloy may further contain manganese in amounts less than 1000 ppm, for example, less than 900 ppm, less than 800 ppm, less than 700 ppm, less than 600 ppm, less than 500 ppm, less than 400 ppm, less than 300 ppm, less than 200 ppm, or less than 100 ppm.

[0036]

[0036] In some cases, the first layer contributes to improving soldering performance. Soldering suitability may be determined by the ability of the layer to be wetted by molten solder. The overall solderability of the material is evaluated herein on a scale from 1 to 5, where 1 indicates poor solderability and 5 indicates excellent solderability. Solderability can be tested to conform to standards such as IPC / ANSI-J-STD002 and IEC60068-2-54.

[0037] Second layer

[0037] In some cases, the second layer can contribute to the performance of resistance welding. Suitability for resistance welding can be determined in part by the compatibility of the thermal and fusion properties of the systems to be welded together. Although we do not wish to be constrained by theory, such compatibility can help limit the formation of brittle metal phases at the joint.

[0038]

[0038] The second layer may constitute 7 vol% to 25 vol% of the entire laminate composite, for example, 8 vol% to 24 vol%, 9 vol% to 23 vol%, 10 vol% to 22 vol%, 11 vol% to 21 vol%, 12 vol% to 20 vol%, 13 vol% to 19 vol%, 14 vol% to 18 vol%, or 15 vol% to 17 vol%. As an upper limit, the second layer may constitute less than 25 vol% of the entire laminate composite, for example, less than 24 vol%, less than 23 vol%, less than 22 vol%, less than 21 vol%, less than 20 vol%, less than 19 vol%, less than 18 vol%, less than 17 vol%, or less than 16 vol%. Regarding the lower limit, the second layer may constitute more than 7 vol% of the total laminate composite material, for example, more than 8 vol%, more than 9 vol%, more than 10 vol%, more than 11 vol%, more than 12 vol%, more than 13 vol%, more than 14 vol%, or more than 15 vol%.

[0039]

[0039] The second layer may include steel or stainless steel. Stainless steel may contain chromium in amounts of 10 wt.% to 25 wt.%, for example, 11 wt.% to 24 wt.%, 12 wt.% to 23 wt.%, 13 wt.% to 22 wt.%, 14 wt.% to 21 wt.%, 15 wt.% to 20 wt.%, 16 wt.% to 19 wt.%, or 17 wt.% to 18 wt.%. With respect to the upper limit, stainless steel may contain less than 25 wt.% of chromium, for example, less than 24 wt.%, less than 23 wt.%, less than 22 wt.%, less than 21 wt.%, less than 20 wt.%, less than 19 wt.%, or less than 18 wt.%. Regarding the lower limit, stainless steel may contain more than 10 wt.% of chromium, for example, more than 11 wt.%, more than 12 wt.%, more than 13 wt.%, more than 14 wt.%, more than 15 wt.%, more than 16 wt.%, or more than 17 wt.%.

[0040]

[0040] Stainless steel may contain nickel in amounts of 0 wt.% to 12 wt.%, for example, 1 wt.% to 11 wt.%, 2 wt.% to 10 wt.%, 3 wt.% to 9 wt.%, 4 wt.% to 8 wt.%, or 5 wt.% to 7 wt.%. Regarding the upper limit, stainless steel may contain nickel in amounts of less than 12 wt.%, for example, less than 11 wt.%, less than 10 wt.%, less than 9 wt.%, less than 8 wt.%, less than 7 wt.%, or less than 6 wt.%. Regarding the lower limit, stainless steel may contain nickel in amounts greater than 0 wt.%, for example, more than 1 wt.%, more than 2 wt.%, more than 3 wt.%, more than 4 wt.%, or more than 5 wt.%.

[0041]

[0041] Suitable stainless steel compositions include, for example, S430, S304, S305, and S316.

[0042] It was observed that when the second layer constituted less than 7 vol% of the laminate composite, performance, such as yield strength, could be impaired.

[0042] Third layer

[0043] The third layer may exhibit high electrical conductivity. Specifically, the electrical conductivity of the third layer may be 100-102% IACS.

[0043]

[0044] The third layer may constitute 40 vol% to 80 vol% of the laminate composite material, for example, 45 vol% to 75 vol%, 50 vol% to 70 vol%, or 55 vol% to 65 vol%. Regarding the upper limit, the third layer may constitute less than 80 vol% of the laminate composite material, for example, less than 75 vol%, less than 70 vol%, less than 65 vol%, or less than 60 vol%. Regarding the lower limit, the third layer may constitute more than 40 vol% of the laminate composite material, for example, more than 45 vol%, more than 50 vol%, or more than 55 vol%.

[0044]

[0045] The third layer may contain more than 90 wt.% of copper, for example, more than 91 wt.%, 92 wt.%, 93 wt.%, 94 wt.%, 95 wt.%, 96 wt.%, 97 wt.%, 98 wt.%, 99 wt.%, 99.5 wt.%, or more than 99.9 wt.%. Suitable copper compositions include, for example, C10200, C10700, and C11000.

[0045] Fourth layer

[0046] As described above, the optional fourth layer may have the same or identical composition and quantity as the second layer. For example, the optional fourth layer may also contain steel or stainless steel. In one embodiment, the second and fourth layers are the same. In one embodiment, the second and fourth layers are different.

[0046]

[0047] Since the second layer is suitable for resistance welding, a suitable fourth layer will also be suitable for resistance welding.

[0047] Fifth layer

[0048] As described above, the optional fifth layer may have the same or identical composition and quantity as the first layer. For example, the optional fifth layer may also contain copper or a copper alloy. In one embodiment, the first and fifth layers are the same. In one embodiment, the first and fifth layers are different.

[0048]

[0049] Since the first layer is suitable for soldering, a suitable fifth layer will also be suitable for soldering.

[0049] Performance characteristics

[0050] The tensile strength of annealed multilayer composites may be in the range of 200 MPa to 430 MPa, as measured by ASTM E8, for example, 210 MPa to 420 MPa, 220 MPa to 410 MPa, 230 MPa to 400 MPa, 240 MPa to 390 MPa, 250 MPa to 380 MPa, 260 MPa to 370 MPa, 270 MPa to 360 MPa, 280 MPa to 350 MPa, 290 MPa to 340 MPa, 300 MPa to 330 MPa, or 310 MPa to 320 MPa. Regarding the upper limit, the tensile strength of multilayer composites may be less than 430 MPa, for example, less than 420 MPa, less than 410 MPa, less than 400 MPa, less than 390 MPa, less than 380 MPa, less than 370 MPa, less than 360 MPa, less than 350 MPa, less than 340 MPa, less than 330 MPa, or less than 320 MPa. Regarding the lower limit, the tensile strength of the multilayer composite material may be greater than 200 MPa, for example, greater than 210 MPa, greater than 220 MPa, greater than 230 MPa, greater than 240 MPa, greater than 250 MPa, greater than 260 MPa, greater than 270 MPa, greater than 280 MPa, greater than 290 MPa, greater than 300 MPa, or greater than 310 MPa. In some embodiments, the tensile strength of the multilayer composite material may be in the range of 350 MPa to 420 MPa.

[0050]

[0051] The tensile modulus of the annealed multilayer composite may be in the range of 120 GPa to 180 GPa, for example, 125 GPa to 175 GPa, 130 GPa to 170 GPa, 135 GPa to 165 GPa, 140 GPa to 160 GPa, or 145 GPa to 155 GPa. Regarding the upper limit, the tensile modulus of the multilayer composite may be less than 180 GPa, for example, less than 175 GPa, less than 170 GPa, less than 165 GPa, less than 160 GPa, less than 155 GPa, or less than 150 GPa. Regarding the lower limit, the tensile modulus of the multilayer composite may be greater than 120 GPa, for example, greater than 125 GPa, greater than 130 GPa, greater than 135 GPa, greater than 140 GPa, or greater than 145 GPa.

[0051]

[0052] In some cases, such as when the first layer constitutes more than 0.9 vol% of the entire laminate composite, the yield strength of the annealed multilayer composite may be in the range of 80 MPa to 180 MPa, as measured by ASTM E8, for example, 85 MPa to 175 MPa, 90 MPa to 170 MPa, 95 MPa to 165 MPa, 100 MPa to 160 MPa, 105 MPa to 155 MPa, 110 MPa to 150 MPa, 115 MPa to 145 MPa, 120 MPa to 140 MPa, or 125 MPa to 135 MPa. Regarding the upper limit, the yield strength of the annealed multilayer composite may be less than 180 MPa, for example, less than 175 MPa, less than 170 MPa, less than 165 MPa, less than 160 MPa, less than 155 MPa, less than 150 MPa, less than 145 MPa, less than 140 MPa, less than 135 MPa, or less than 130 MPa. Regarding the lower limit, the yield strength of the multilayer composite material may be greater than 80 MPa, for example, greater than 85 MPa, greater than 90 MPa, greater than 95 MPa, greater than 100 MPa, greater than 105 MPa, greater than 110 MPa, greater than 115 MPa, greater than 120 MPa, or greater than 125 MPa.

[0052]

[0053] If the first layer constitutes 0.7 vol% to 1.4 vol% of the entire multilayer composite, the yield strength of the annealed multilayer composite may be in the range of 62 MPa to 80 MPa, for example, 63 MPa to 79 MPa, 64 MPa to 78 MPa, 65 MPa to 77 MPa, 66 MPa to 76 MPa, 67 MPa to 75 MPa, 68 MPa to 74 MPa, 69 MPa to 73 MPa, or 70 MPa to 72 MPa. Regarding the upper limit, the yield strength of the multilayer composite may be less than 80 MPa, for example, less than 79 MPa, less than 78 MPa, less than 77 MPa, less than 76 MPa, less than 75 MPa, less than 74 MPa, less than 73 MPa, less than 72 MPa, or less than 71 MPa. Regarding the lower limit, the yield strength of the multilayer composite material may be greater than 62 MPa, for example, greater than 63 MPa, 64 MPa, 65 MPa, 66 MPa, 67 MPa, 68 MPa, 69 MPa, 70 MPa, or 71 MPa.

[0053]

[0054] The flexural modulus of the annealed multilayer composite may be in the range of 135 GPa to 190 GPa, for example, 140 GPa to 185 GPa, 145 GPa to 180 GPa, 150 GPa to 175 GPa, 155 GPa to 170 GPa, or 160 GPa to 165 GPa. Regarding the upper limit, the flexural modulus of the annealed multilayer composite may be less than 190 GPa, for example, less than 185 GPa, less than 180 GPa, less than 175 GPa, or less than 170 GPa or less than 165 GPa. Regarding the lower limit, the flexural modulus of the annealed multilayer composite may be greater than 135 GPa, for example, greater than 140 GPa, greater than 145 GPa, greater than 150 GPa, greater than 155 GPa, or greater than 160 GPa.

[0054]

[0055] The modulus of elasticity of multilayer composites, when calculated using data measured by tensile tests according to ASTM E8, may be in the range of 100 GPa to 200 GPa, for example, 110 GPa to 190 GPa, 120 GPa to 180 GPa, 130 GPa to 170 GPa, or 140 GPa to 160 GPa. Regarding the upper limit, the modulus of elasticity of multilayer composites may be less than 200 GPa, for example, less than 190 GPa, less than 180 GPa, less than 170 GPa, less than 160 GPa, or less than 150 GPa. Regarding the lower limit, the modulus of elasticity of multilayer composites may be greater than 100 GPa, for example, greater than 110 GPa, greater than 120 GPa, greater than 130 GPa, or greater than 140 GPa.

[0055]

[0056] Multilayer composites may exhibit elongation at break in the range of 6% to 30%, for example, 7% to 29%, 8% to 28%, 9% to 27%, 10% to 26%, 11% to 25%, 12% to 24%, 13% to 23%, 14% to 22%, 15% to 21%, 16% to 20%, or 17% to 19%. Regarding the upper limit, multilayer composites may exhibit elongation at break of less than 29%, less than 28%, less than 27%, less than 26%, less than 25%, less than 24%, less than 23%, less than 22%, less than 21%, less than 20%, less than 19%, or less than 18%. Regarding the lower limit, multilayer composites may exhibit elongation at break of over 8%, over 9%, over 10%, over 11%, over 12%, over 13%, over 14%, over 15%, over 16%, or over 17%.

[0056]

[0057] Multilayer composites may exhibit bending radii (GW / BW) of less than 0.051 mm (0.002 inches), for example, less than 0.038 mm (0.0015 inches), less than 0.025 mm (0.001 inches), less than 0.023 mm (0.0009 inches), less than 0.020 mm (0.0008 inches), less than 0.018 mm (0.0007 inches), less than 0.015 mm (0.0006 inches), less than 0.013 mm (0.0005 inches), less than 0.010 mm (0.0004 inches), less than 0.008 mm (0.0003 inches), less than 0.005 mm (0.0002 inches), or less than 0.003 mm (0.0001 inches).

[0057]

[0058] The thermal conductivity of the multilayer composite material may be in the range of 45 W / mK to 220 W / mK, for example, 50 W / mK to 210 W / mK, 60 W / mK to 200 W / mK, 70 W / mK to 190 W / mK, 80 W / mK to 180 W / mK, 90 W / mK to 170 W / mK, 100 W / mK to 160 W / mK, 110 W / mK to 150 W / mK, or 120 W / mK to 140 W / mK. As for the upper limit, the thermal conductivity may be less than 220 W / mK, for example, less than 210 W / mK, less than 200 W / mK, less than 190 W / mK, less than 180 W / mK, less than 170 W / mK, less than 160 W / mK, less than 150 W / mK, or less than 140 W / mK. Regarding the lower limit, the thermal conductivity may be greater than 45 W / mK, for example, greater than 50 W / mK, greater than 60 W / mK, greater than 70 W / mK, greater than 80 W / mK, greater than 90 W / mK, greater than 100 W / mK, greater than 110 W / mK, greater than 120 W / mK, or greater than 130 W / mK.

[0058]

[0059] The coefficient of thermal expansion (CTE) of multilayer composites may be in the range of 12 ppm / °C to 17 ppm / °C, for example, 12.5 ppm / °C to 16.5 ppm / °C, 13 ppm / °C to 16 ppm / °C, 13.5 ppm / °C to 15.5 ppm / °C, or 14 ppm / °C to 15 ppm / °C. Regarding the upper limit, the CTE of multilayer composites may be less than 17 ppm / °C, for example, less than 16.5 ppm / °C, less than 16 ppm / °C, less than 15.5 ppm / °C, less than 15 ppm / °C, or less than 14.5 ppm / °C. Regarding the lower limit, the CTE of multilayer composites may be greater than 12 ppm / °C, for example, greater than 12.5 ppm / °C, greater than 13 ppm / °C, greater than 13.5 ppm / °C, or greater than 14 ppm / °C.

[0059]

[0060] The density of the multilayer composite material is 8.0 g / cm³. 3 ~10g / cm 3 For example, within the range of 8.1 g / cm³. 3 ~9.9g / cm 3 8.2 g / cm³ 3 ~9.8g / cm 3 8.3 g / cm³ 3 ~9.7g / cm 3 8.4 g / cm³3 ~9.6 g / cm 3 、8.5 g / cm 3 ~9.5 g / cm 3 、8.5 g / cm 3 ~9.4 g / cm 3 、8.6 g / cm 3 ~9.3 g / cm 3 、8.7 g / cm 3 ~9.3 g / cm 3 、8.8 g / cm 3 ~9.2 g / cm 3 、or 8.9 g / cm 3 ~9.1 g / cm 3 It may also be within the range of. Regarding the upper limit, the density of the multi-layer composite material is less than 10 g / cm 3 less than, for example, 9.9 g / cm 3 less than, 9.8 g / cm 3 less than, 9.7 g / cm 3 less than, 9.6 g / cm 3 less than, 9.5 g / cm 3 less than, 9.4 g / cm 3 less than, 9.3 g / cm 3 less than, 9.2 g / cm 3 less than, 9.1 g / cm 3 less than, or 9.0 g / cm 3 less than and may also be acceptable. Regarding the lower limit, the density of the multi-layer composite material is greater than 8.0 g / cm 3 more than, for example, 8.1 g / cm 3 more than, 8.2 g / cm 3 more than, 8.3 g / cm 3 more than, 8.4 g / cm 3 more than, 8.5 g / cm 3 more than, 8.6 g / cm 3 more than, 8.7 g / cm 3 more than, 8.8 g / cm 3 more than, or 8.9 g / cm 3 more than and may also be acceptable.

Code 0060

[0061] Conventional materials used for connecting individual batteries within a battery pack are generally nickel-based, such as metallic nickel strips. While nickel may exhibit several desirable properties, such as suitability for resistance welding and good corrosion resistance, its cost and potential toxicity can make its use less desirable. Furthermore, the use of nickel-based materials in high-power applications can lead to reduced battery performance and safety due to resistive heating.

[0061]

[0062] The metal laminate composites of this disclosure may be particularly suitable for use, for example, as connector tabs in battery packs. The multilayer laminate composites of this disclosure exhibit higher electrical conductivity compared to, for example, nickel, which can be particularly advantageous in high-power applications. To minimize energy loss and enable higher peak current, it is desirable that portable power battery packs exhibit the lowest possible electrical resistance between cells. It is also desirable that the mechanical connections between cells can withstand numerous drops, tool vibrations, shocks, and temperature cycles. To avoid overheating of the internal separator material of the cells, the materials used should be weldable using minimal welding energy. The materials used should be economical without sacrificing performance.

[0062]

[0063] Specifically, the multilayer metal laminate compositions of this disclosure exhibit significantly higher conductivity than nickel. This improved conductivity can extend the lifespan of battery packs and, at the same time, prevent high peak currents when necessary.

[0063]

[0064] The multilayer metal laminate compositions of this disclosure are suitable for use as connector tabs for lithium-ion batteries, nickel-metal hydride batteries, and alkaline batteries, for example.

[0065] As shown in Figure 1, the first layer 10 may be an outer layer. The second layer 12 may be sandwiched between the first layer 10 and the third layer 14. The second layer may be bonded to both the first layer 10 and the third layer 14. The third layer 14 may be sandwiched between the second layer 12 and the fourth layer 16. In addition to being bonded to the second layer 12, the third layer 14 may also be bonded to the fourth layer 16. The fourth layer 16 may be sandwiched between the third layer 14 and the fifth layer 18. In addition to being bonded to the third layer 14, the fourth layer may also be bonded to the fifth layer 18. [Examples]

[0064] Examples 1-8

[0066] Fifteen exemplary multilayer laminate compositions (Examples 1-8 and Comparative Examples A-G), each containing five layers, were evaluated. Specifically, in Examples 1-4 and Comparative Example A, the first and fifth layers were copper alloys containing 90% copper, the second and fourth layers contained stainless steel, and the third layer contained copper. In Examples 5-8 and Comparative Example B, the first and fifth layers were copper alloys containing 70% copper, the second and fourth layers contained stainless steel, and the third layer contained copper. Finally, in Comparative Examples C-G, the first and fifth layers contained nickel (Ni), the second and fourth layers contained stainless steel (SS), and the third layer contained copper (Cu). The volume percentage of each layer (relative to the total volume of the composition) is shown below in Table 1. As disclosed herein, the examples adopted a higher volume percentage (greater than 7 vol%) in the second layer.

[0065] [Table 1]

[0067] In each example, the tensile modulus (TM), flexural modulus (FM), yield strength (YS), electrical conductivity (EC), thermal conductivity (TC), coefficient of thermal expansion (CTE), and density (ρ) were measured for the annealed samples. The results are shown in Table 2 below.

[0066] [Table 2]

[0068] As shown in Table 2, Examples 1-8 achieved a surprisingly significant improvement in yield strength. All examples showed yield strength performance exceeding 68 MPa, but the examples in which the outer layer constituted more than 0.9 vol% of the laminate composite material showed even higher yield strength, for example, significantly exceeding 80 MPa. For comparison, the comparative examples averaged approximately 68 MPa, and none achieved a yield strength as high as 80 MPa. Importantly, none of the other mechanical properties were impaired as a result of the above improvement in yield strength.

[0067]

[0069] In particular, the compositions disclosed herein show a significant improvement in yield strength compared to the comparative examples, even when not fully annealed. Specifically, as shown in Table 3, the examples perform remarkably well at 1 / 4 hardness (1 / 4H), 1 / 2 hardness (1 / 2H), and 3 / 4 hardness (3 / 4H).

[0068] [Table 3]

[0070] As shown above, the examples demonstrate significantly superior functionality compared to compositions containing nickel in the outer layer (Comparative Examples C-G). Surprisingly, the examples also demonstrate superior functionality compared to compositions in which the second layer constitutes less than 7 vol% of the total laminate composite material (Comparative Examples A and B).

[0069] Solderability

[0071] The solderability of the four multilayer laminate composite materials shown in Table 1 was determined by testing them using the "dip and look" test. In this test, the samples were first cleaned and then immersed in tin solder. Performance was evaluated on a pass / fail basis, with pass indicating that the solder appeared smooth and continuous with no changes or irregularities in texture.

[0070] [Table 4]

[0072] Therefore, the multilayer laminate composites disclosed herein achieve desirable solderability while simultaneously providing a significant improvement in yield strength. In contrast, while the comparative examples performed well in terms of solderability, they failed to demonstrate superior performance in terms of a synergistic combination of yield strength and solderability.

[0071] Embodiment

[0073] Any reference to a series of embodiments used below should be understood as referring separately to each of those embodiments (for example, “Embodiments 1-4” should be understood as “Embodiments 1, 2, 3, or 4”).

[0072]

[0074] Embodiment 1: A metal laminate composite comprising: a first layer containing a copper-containing compound; a second layer selected from steel or stainless steel; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound, wherein the composite exhibits an electrical conductivity in the range of 40%IACS to 82%IACS as determined by ASTM E1004.

[0073]

[0075] Embodiment 2: The metal laminate composite of Embodiment 1, wherein the first layer has an conductivity of less than 10% IACS.

[0076] Embodiment 3: A metal laminate composite of Embodiment 1 or Embodiment 2, wherein the metal laminate exhibits excellent corrosion resistance as determined by SAE / USCAR2 5.6.2 and ASTM B117.

[0074]

[0077] Embodiment 4: A metal laminate composite material according to any of Embodiments 1 to 3, wherein the copper-containing compound comprises copper, a copper alloy, or a combination thereof.

[0078] Embodiment 5: A metal laminate composite material according to any of Embodiments 1 to 4, wherein the copper-containing compound includes a copper-nickel alloy.

[0075]

[0079] Embodiment 6: The metal laminate composite material of Embodiment 5, wherein the copper-nickel alloy contains 60 wt.% to 95 wt.% copper and 5 wt.% to 40 wt.% nickel.

[0080] Embodiment 7: The metal laminate composite of Embodiment 6, wherein the copper-nickel alloy contains more than 5 wt.% and less than 35 wt.% nickel.

[0076]

[0081] Embodiment 8: A metal laminate composite material according to any of Embodiments 1 to 7, wherein the first layer constitutes 0.9 vol% to 10 vol% of the laminate composite material; the second layer constitutes 7 vol% to 25 vol% of the laminate composite material; the third layer constitutes 40 vol% to 80 vol% of the laminate composite material; the fourth layer constitutes 7 vol% to 25 vol% of the laminate composite material; and / or the fifth layer constitutes 0.9 vol% to 10 vol% of the laminate composite material.

[0077]

[0082] Embodiment 9: A metal laminate composite material according to any of Embodiments 1 to 8, wherein the first layer and the fifth layer are copper alloys.

[0083] Embodiment 10: A metal laminate composite material according to any of Embodiments 1 to 9, exhibiting a tensile strength in the range of 350 MPa to 420 MPa.

[0078]

[0084] Embodiment 11: A metal laminate composite material according to any of Embodiments 1 to 10, exhibiting a yield strength in the range of 280 MPa to 400 MPa.

[0085] Embodiment 12: A metal laminate composite material according to any of Embodiments 1 to 11, exhibiting a flexural modulus in the range of 140 GPa to 182 GPa.

[0079]

[0086] Embodiment 13: A metal laminate composite material according to any of Embodiments 1 to 12, exhibiting an elastic modulus in the range of 120 GPa to 160 GPa.

[0087] Embodiment 14: Connector tab for a lithium-ion battery pack comprising a metal laminate composite, wherein the metal laminate composite comprises: a first layer comprising a copper-containing compound; a second layer selected from steel or stainless steel; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer comprising a copper-containing compound, the composite exhibiting conductivity in the range of 40%IACS to 82%IACS as measured in accordance with ASTM E1004.

[0080]

[0088] Embodiment 15: A connector tab of Embodiment 14, wherein the first and fifth layers comprise a copper-nickel alloy containing 60 wt.% to 95 wt.% copper and 5 wt.% to 40 wt.% nickel.

[0081]

[0089] Embodiment 16: A metal laminate composite comprising: a first layer containing a copper-containing compound; a second layer containing steel or stainless steel; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound, wherein the first layer constitutes more than 0.9 vol% of the metal laminate composite; the second layer constitutes at least 7 vol% of the metal laminate composite; the composite exhibits a yield strength exceeding 80 MPa; and the metal laminate composite passes a Dip and Look solderability test comprising the steps of: washing a sample of the composite; immersing the washed sample in a solder composition; and evaluating the smoothness and continuity of the solder on the sample.

[0082]

[0090] Embodiment 17: The metal laminate composite of Embodiment 16, wherein the composite exhibits conductivity in the range of 40%IACS to 82%IACS as defined by ASTM E1004.

[0091] Embodiment 18: A metal laminate composite material in either Embodiment 16 or Embodiment 17, wherein the copper-containing compound comprises copper, a copper alloy, or a combination thereof.

[0083]

[0092] Embodiment 19: A metal laminate composite material from any of Embodiments 16 to 18, wherein the copper-containing compound includes a copper-nickel alloy.

[0093] Embodiment 20: The metal laminate composite material of Embodiment 19, wherein the copper-nickel alloy contains 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

[0084]

[0094] Embodiment 21: A metal laminate composite material according to any of Embodiments 16 to 20, wherein the first layer constitutes 0.9 vol% to 15 vol% of the metal laminate composite material; the second layer constitutes 7 vol% to 25 vol% of the metal laminate composite material; the third layer constitutes 35 vol% to 85 vol% of the metal laminate composite material; the fourth layer constitutes 7 vol% to 25 vol% of the metal laminate composite material; and / or the fifth layer constitutes 0.9 vol% to 15 vol% of the laminate composite material.

[0085]

[0095] Embodiment 22: A metal laminate composite material of any of Embodiments 16 to 21, wherein the first layer and the fifth layer are copper alloys.

[0096] Embodiment 23: A metal laminate composite material from any of Embodiments 16 to 22, exhibiting a tensile modulus in the range of 120 GPa to 180 GPa.

[0086]

[0097] Embodiment 24: A metal laminate composite material exhibiting a flexural modulus greater than 135 GPa, as described in any of Embodiments 16 to 23.

[0098] Embodiment 25: A metal laminate composite material from any of Embodiments 16 to 24, exhibiting a thermal conductivity in the range of 50 W / mK to 220 W / mK.

[0087]

[0099] Embodiment 26: A connector tab for a lithium-ion battery pack comprising a metal laminate composite, wherein the metal laminate composite comprises: a first layer comprising a copper-containing compound; a second layer selected from steel or stainless steel; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer comprising a copper-containing compound, wherein the composite exhibits conductivity in the range of 40%IACS to 82%IACS as measured in accordance with ASTM E1004, the first layer constituting more than 0.9 vol% of the metal laminate composite; and the second layer constituting more than 7 vol% of the metal laminate composite.

[0088]

[0100] Embodiment 27: A connector tab of Embodiment 26, wherein the first and fifth layers comprise a copper-nickel alloy containing 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

[0089]

[0101] Embodiment 28: A metal laminate composite comprising: a first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate; a second layer containing steel or stainless steel in an amount of more than 7 vol% of the metal laminate; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound; exhibiting a yield strength exceeding 62 MPa; and passing a dip-and-look solderability test comprising the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample.

[0090]

[0102] Embodiment 29: The metal laminate composite of Embodiment 28, wherein the copper-containing compound comprises copper, a copper alloy, or a combination thereof.

[0103] Embodiment 30: A metal laminate composite material according to Embodiment 28 or Embodiment 29, wherein the copper-containing compound includes a copper-nickel alloy.

[0091]

[0104] Embodiment 31: The metal laminate composite material of Embodiment 30, wherein the copper-nickel alloy contains 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

[0105] Embodiment 32: A metal laminate composite comprising: a first layer containing a copper-containing compound in an amount exceeding 0.9 vol% of the metal laminate; a second layer containing steel or stainless steel in an amount exceeding 7 vol% of the metal laminate; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound; exhibiting a yield strength of over 293 MPa when annealed to 1 / 4H, over 390 MPa when annealed to 1 / 2H, or over 456 MPa when annealed to 3 / 4H; and passing a dip-and-look solderability test comprising the steps of washing a sample of the composite, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample.

[0092]

[0106] Embodiment 33: A metal laminate composite comprising: a first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate; a second layer containing steel or stainless steel in an amount exceeding 7 vol% of the metal laminate; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound; exhibiting a yield strength exceeding 62 MPa; and passing a dip-and-look solderability test comprising the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample.

[0093]

[0107] Embodiment 34: A metal laminate composite comprising: a first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate; a second layer containing steel or stainless steel in an amount exceeding 7 vol% of the metal laminate; a third layer selected from copper or a copper alloy; an optional fourth layer selected from steel or stainless steel; and an optional fifth layer containing a copper-containing compound; exhibiting a yield strength of over 233 MPa when annealed to 1 / 4H, over 310 MPa when annealed to 1 / 2H, or over 362 MPa when annealed to 3 / 4H; and passing a dip-and-look solderability test comprising the steps of washing a sample of the composite, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample.

Claims

1. A metal laminate composite material, A first layer containing a copper-containing compound in an amount exceeding 0.9 vol% of the metal laminate, A second layer comprising steel or stainless steel in an amount exceeding 7 vol% of the aforementioned metal laminate, A third layer selected from copper or a copper alloy, An optional fourth layer selected from steel or stainless steel, An optional fifth layer containing a copper-containing compound and Includes, It exhibits a yield strength exceeding 80 MPa. The dip-and-look solderability test includes the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample, and the material passes the test. Metal laminate composite material.

2. The metal laminate composite material according to claim 1, exhibiting conductivity in the range of 40% IACS to 82% IACS as determined by ASTM E1004.

3. The metal laminate composite material according to claim 1, wherein the copper-containing compound comprises copper, a copper alloy including a copper-nickel alloy, or a combination thereof.

4. The metal laminate composite material according to claim 4, wherein the copper-nickel alloy contains 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

5. The first layer constitutes 0.9 vol% to 15 vol% of the metal laminate composite material. The second layer constitutes 7 vol% to 25 vol% of the metal laminate composite material. The third layer constitutes 35 vol% to 85 vol% of the metal laminate composite material. The fourth layer constitutes 7 vol% to 25 vol% of the metal laminate composite material, and / or The fifth layer constitutes 0.9 vol% to 15 vol% of the metal laminate composite material. The metal laminate composite material according to claim 1.

6. The metal laminate composite material according to claim 1, wherein the first layer and the fifth layer are copper alloys.

7. The metal laminate composite material according to claim 1, exhibiting a tensile modulus in the range of 120 GPa to 180 GPa, and / or a flexural modulus exceeding 135 GPa, and / or a thermal conductivity in the range of 45 W / mK to 220 W / mK.

8. A connector tab for a lithium-ion battery pack containing a metal laminate composite material, wherein the metal laminate composite material is A first layer containing a copper-containing compound, A second layer selected from steel or stainless steel, A third layer selected from copper or a copper alloy, An optional fourth layer selected from steel or stainless steel, An optional fifth layer containing a copper-containing compound and Includes, The composite material exhibits an electrical conductivity in the range of 40% IACS to 82% IACS, as measured in accordance with ASTM E1004. The first layer constitutes more than 0.9 vol% of the metal laminate composite material, The second layer constitutes more than 7 vol% of the metal laminate composite material. Connector tab.

9. The connector tab according to claim 8, wherein the first and fifth layers comprise a copper-nickel alloy containing 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

10. A metal laminate composite material, A first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate, A second layer comprising steel or stainless steel in an amount exceeding 7 vol% of the aforementioned metal laminate, A third layer selected from copper or a copper alloy, An optional fourth layer selected from steel or stainless steel, An optional fifth layer containing a copper-containing compound and Includes, It exhibits a yield strength exceeding 62 MPa. The dip-and-look solderability test includes the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample, and the material passes the test. Metal laminate composite material.

11. The metal laminate composite material according to claim 10, wherein the copper-containing compound comprises copper, a copper alloy including a copper-nickel alloy, or a combination thereof.

12. The metal laminate composite material according to claim 11, wherein the copper-nickel alloy contains 65 wt.% to 95 wt.% copper and 5 wt.% to 35 wt.% nickel.

13. A metal laminate composite material, A first layer containing a copper-containing compound in an amount exceeding 0.9 vol% of the metal laminate, A second layer comprising steel or stainless steel in an amount exceeding 7 vol% of the aforementioned metal laminate, A third layer selected from copper or a copper alloy, An optional fourth layer selected from steel or stainless steel, An optional fifth layer containing a copper-containing compound and Includes, When annealed to 1 / 4H, it exhibits a yield strength of over 293 MPa, when annealed to 1 / 2H, it exhibits a yield strength of over 390 MPa, and when annealed to 3 / 4H, it exhibits a yield strength of over 456 MPa. The dip-and-look solderability test includes the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample, and the material passes the test. Metal laminate composite material.

14. A metal laminate composite material, A first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate, A second layer comprising steel or stainless steel in an amount exceeding 7 vol% of the aforementioned metal laminate, A third layer selected from copper or a copper alloy, An optional fourth layer selected from steel or stainless steel, An optional fifth layer containing a copper-containing compound and Includes, It exhibits a yield strength exceeding 62 MPa. The dip-and-look solderability test includes the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample, and the material passes the test. Metal laminate composite material.

15. A metal laminate composite material, A first layer containing a copper-containing compound in an amount of 0.7 vol% to 1.4 vol% of the metal laminate, A second layer comprising steel or stainless steel in an amount exceeding 7 vol% of the aforementioned metal laminate, A third layer selected from copper or a copper alloy, A fourth optional layer selected from steel or stainless steel and An optional fifth layer containing a copper-containing compound and Includes, When annealed to 1 / 4H, it exhibits a yield strength of over 233 MPa, when annealed to 1 / 2H, it exhibits a yield strength of over 310 MPa, and when annealed to 3 / 4H, it exhibits a yield strength of over 362 MPa. The dip-and-look solderability test includes the steps of washing a sample of the composite material, immersing the washed sample in a solder composition, and evaluating the smoothness and continuity of the solder on the sample, and the material passes the test. Metal laminate composite material.

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