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What effects may indentations on the foil surface have on finished product performance when welding multi-layer laminated flexible connections on a polymer diffusion welding machine?
Nov 11,2026
When a polymer diffusion welding machine welds multi-layer laminated flexible connections, metallurgical bonding between layers is formed by temperature, pressure and holding time. Indentations and pits on the foil surface may look like a minor appearance issue, but they can change interlayer contact and diffusion conditions, and thus affect finished product performance.
I. Insufficient interlayer contact and incomplete diffusion
1. At indentation recesses the foil is difficult to press tightly against the adjacent layer, leaving small gaps between layers.
2. Heat and pressure transfer efficiency at the gaps drops, interface diffusion is insufficient and bonding strength is low.
3. In multi-layer stacking, indentations accumulate layer by layer, gaps grow and the bonding state differs between the ends and the middle.
II. Interface microcracks and the risk of delamination and peeling
1. Stress concentrates at indentation edges, and interface microcracks may form during pressing and cooling.
2. Areas with insufficient bonding carry a risk of delamination and peeling in later bending and stamping.
3. Foil with deeper indentations has uneven local thickness after stacking and may become a crack initiation point under load.
III. Lower conductivity and poorer resistance consistency
1. Interlayer gaps reduce the effective contact area, and the DC resistance of the flexible connection may be high.
2. Bonding differs between layers, resistance distribution is uneven, and local temperature rise differs noticeably when current flows.
3. Resistance fluctuation may propagate to downstream assembly and machine testing, affecting batch consistency.
IV. Effects on appearance, dimensions and later assembly
1. Indentations form pits and color differences on the product surface, and appearance consistency drops.
2. Total thickness deviation increases after stacking, and assembly clearance and clamping force may change accordingly.
3. When the end indentation is deep, the edge of the welding area may warp and affect fitting with the busbar.
Wuxi Haifei Intelligent Equipment Co., Ltd. official website: https://www.haifeiwelder.com/
Wuxi Haifei Intelligent Equipment Co., Ltd. has been dedicated to the research and production of diffusion welding machines for 17 years. The company has passed the ISO9001 quality management system certification, the national 3C certification and the CE certification. It is a national high-tech enterprise, a Specialized, Refined, Distinctive and Innovative enterprise of Jiangsu Province, a Specialized, Refined, Distinctive and Innovative enterprise of Wuxi City, and a Gazelle enterprise of the Southern Jiangsu National Independent Innovation Demonstration Zone. If you are interested in our diffusion welding machines, please contact us at liuyiyu@jshaifei.com.
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
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Email: wushijie@jshaifei.com