{
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    "id": "term:tab-welding",
    "type": "Term",
    "label": "Tab welding",
    "properties": {
      "id": "tab-welding",
      "name": "Tab welding",
      "section": "topic-manufacturing",
      "definition": "Joining the bundle of foil tabs to the terminal tab, usually by ultrasonic welding, which bonds thin foils without melting them; laser welding is used for can-to-cap and busbar joints. A weak weld raises resistance and can fail in service.",
      "related": [
        "tab",
        "ultrasonic-welding",
        "laser-welding",
        "internal-resistance",
        "tab-pull-test"
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      "lesson": "fundamentals/cell-production/#assembly",
      "url": "https://lemonergy.com/learn/glossary/tab-welding/",
      "mentions": [
        "busbar"
      ]
    }
  },
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      "id": "topic:topic-manufacturing",
      "type": "Topic",
      "label": "Manufacturing",
      "properties": {
        "id": "topic-manufacturing",
        "name": "Manufacturing",
        "lede": "The steps that turn powders and foils into a finished cell, in production order.",
        "context": "Place operations and quality checks in process order.",
        "example": "An electrode can meet coating mass targets but fail adhesion or moisture checks later.",
        "lesson_url": "https://lemonergy.com/learn/fundamentals/cell-production/",
        "lesson_label": "Open production"
      }
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    {
      "id": "term:tab",
      "type": "Term",
      "label": "Tab",
      "properties": {
        "id": "tab",
        "name": "Tab",
        "section": "topic-components",
        "definition": "The strip of metal that connects an electrode’s foil to the cell terminal: nickel or copper on the negative side, aluminium on the positive. Tab count and width set much of a cell’s resistance and heat generation.",
        "related": [
          "current-collector",
          "tab-welding",
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        "example": {
          "title": "Electrical and thermal paths",
          "text": "Tab geometry can change electrical resistance and heat flow without changing active-material capacity."
        },
        "url": "https://lemonergy.com/learn/glossary/tab/",
        "mentions": [
          "electrode",
          "heat-generation"
        ]
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    },
    {
      "id": "term:ultrasonic-welding",
      "type": "Term",
      "label": "Ultrasonic welding",
      "properties": {
        "id": "ultrasonic-welding",
        "name": "Ultrasonic welding",
        "section": "topic-manufacturing",
        "definition": "Joining metals by pressing them together and vibrating one part at ultrasonic frequency, so friction scrubs the surfaces clean and bonds them below the melting point. It is the standard way to weld stacks of thin aluminium and copper foil.",
        "related": [
          "tab-welding",
          "laser-welding",
          "tab"
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        "url": "https://lemonergy.com/learn/glossary/ultrasonic-welding/",
        "mentions": [
          "copper-foil"
        ]
      }
    },
    {
      "id": "term:laser-welding",
      "type": "Term",
      "label": "Laser welding",
      "properties": {
        "id": "laser-welding",
        "name": "Laser welding",
        "section": "topic-manufacturing",
        "definition": "Joining metal with a focused laser beam, used to seal cans, attach caps and connect busbars to cell terminals. It is fast and precise but sensitive to gaps and reflectivity, so copper joints need special wavelengths or beam shaping.",
        "related": [
          "ultrasonic-welding",
          "tab-welding",
          "busbar",
          "can"
        ],
        "url": "https://lemonergy.com/learn/glossary/laser-welding/",
        "mentions": []
      }
    },
    {
      "id": "term:internal-resistance",
      "type": "Term",
      "label": "Internal resistance",
      "properties": {
        "id": "internal-resistance",
        "name": "Internal resistance",
        "abbr": "IR",
        "aka": [
          "DC resistance",
          "DCIR"
        ],
        "section": "topic-units",
        "definition": "The resistance a cell presents to current, from its foils, electrolyte, interfaces and the reactions themselves. It converts part of the delivered energy into heat, sets the voltage drop under load, and rises as the cell ages; a large automotive cell has about a milliohm, a small cylindrical cell tens.",
        "unit": "mΩ",
        "related": [
          "ohms-law",
          "ir-drop",
          "impedance-rise",
          "dcir",
          "area-specific-resistance",
          "resistance-capacity-product"
        ],
        "lesson": "fundamentals/battery-basics/#datasheet",
        "url": "https://lemonergy.com/learn/glossary/internal-resistance/",
        "mentions": [
          "electrolyte",
          "cylindrical-cell"
        ]
      }
    },
    {
      "id": "term:tab-pull-test",
      "type": "Term",
      "label": "Tab pull-strength test",
      "properties": {
        "id": "tab-pull-test",
        "name": "Tab pull-strength test",
        "aka": [
          "weld pull test",
          "pull test",
          "weld peel test"
        ],
        "section": "topic-testing",
        "definition": "Pulling a welded tab or busbar joint until it breaks, recording the peak force and where the break occurred, to verify weld quality. It is destructive, so samples are taken from each batch or shift; failure through the parent foil rather than at the weld interface indicates a sound joint.",
        "related": [
          "tab-welding",
          "ultrasonic-welding",
          "laser-welding",
          "tab",
          "busbar"
        ],
        "url": "https://lemonergy.com/learn/glossary/tab-pull-test/",
        "mentions": []
      }
    },
    {
      "id": "term:busbar",
      "type": "Term",
      "label": "Busbar",
      "properties": {
        "id": "busbar",
        "name": "Busbar",
        "section": "topic-pack",
        "definition": "A rigid copper or aluminium conductor that joins cell terminals into series and parallel groups, and modules into the pack. Its cross-section is sized for current and heating, and its joints — welded or bolted — are a classic source of resistance and failure.",
        "related": [
          "series-parallel",
          "terminal",
          "laser-welding",
          "internal-resistance",
          "wire-bonding"
        ],
        "url": "https://lemonergy.com/learn/glossary/busbar/",
        "mentions": []
      }
    },
    {
      "id": "lesson:fundamentals/cell-production/",
      "type": "Lesson",
      "label": "Lesson 3 · Cell production",
      "properties": {
        "url": "https://lemonergy.com/learn/fundamentals/cell-production/"
      }
    },
    {
      "id": "reference:liu-manufacturing",
      "type": "Reference",
      "label": "Current and future lithium-ion battery manufacturing",
      "properties": {
        "title": "Current and future lithium-ion battery manufacturing",
        "publisher": "iScience",
        "url": "https://doi.org/10.1016/j.isci.2021.102332",
        "type": "Review article",
        "scope": "Electrode preparation, cell assembly, formation and manufacturing trade-offs.",
        "year": 2021,
        "authors": [
          "Yangtao Liu",
          "Ruihan Zhang",
          "Jun Wang",
          "Yan Wang"
        ],
        "accessed": "2026-10-27"
      }
    }
  ]
}