Proceedings ArticleDOI
Joining Technologies for Automotive Lithium-Ion Battery Manufacturing: A Review
S. Shawn Lee,Tae Hyung Kim,S. Jack Hu,Wayne W. Cai,Jeffrey A. Abell +4 more
- pp 541-549
TLDR
In this paper, a comprehensive review of joining technologies and processes for automotive lithium-ion battery manufacturing is presented, including resistance welding, laser welding, ultrasonic welding and mechanical joining.Abstract:
Automotive battery packs for electric vehicles (EV), hybrid electric vehicles (HEV), and plug-in hybrid electric vehicles (PHEV) typically consist of a large number of battery cells. These cells must be assembled together with robust mechanical and electrical joints. Joining of battery cells presents several challenges such as welding of highly conductive and dissimilar materials, multiple sheets joining, and varying material thickness combinations. In addition, different cell types and pack configurations have implications for battery joining methods. This paper provides a comprehensive review of joining technologies and processes for automotive lithium-ion battery manufacturing. It details the advantages and disadvantages of the joining technologies as related to battery manufacturing, including resistance welding, laser welding, ultrasonic welding and mechanical joining, and discusses corresponding manufacturing issues. Joining processes for electrode-to-tab, tab-to-tab (tab-to-bus bar), and module-to-module assembly are discussed with respect to cell types and pack configuration.Copyright © 2010 by ASME and General Motorsread more
Citations
More filters
Journal ArticleDOI
Current status and challenges for automotive battery production technologies
TL;DR: An introductory summary of the state-of-the-art production technologies for automotive LIBs is presented and the importance of understanding relationships between the production process and battery performance is discussed.
Journal ArticleDOI
Post-lithium-ion battery cell production and its compatibility with lithium-ion cell production infrastructure
Fabian Duffner,Niklas Kronemeyer,Jens Tübke,Jens Leker,Jens Leker,Martin Winter,Martin Winter,Richard Schmuch +7 more
TL;DR: In this article, the authors survey the current production status of several representative post-lithium-ion batteries and offer an industrial-scale manufacturing outlook and evaluate the manufacturing compatibility of each technology with the lithium-ion production infrastructure and discuss the implications for processing costs.
Journal ArticleDOI
Joining Technologies for Automotive Battery Systems Manufacturing
TL;DR: In this paper, the applicability of major and emerging joining techniques to support the wide range of joining requirements that exist during battery pack manufacturing is reviewed, and the maturity and application potential of current joining technologies are mapped with respect to manufacturing readiness levels.
Journal ArticleDOI
End-of-life (EOL) issues and options for electric vehicle batteries
Monsuru Ramoni,Hong-Chao Zhang +1 more
TL;DR: In this paper, the authors proposed remanufacturing as the alternate and appropriate end-of-life (EOL) option for the EV batteries, but there are many issues that make recycling less justifiable.
Journal ArticleDOI
Characterization of Joint Quality in Ultrasonic Welding of Battery Tabs
TL;DR: In this article, the authors identify a number of critical weld attributes that determine the quality of welds by experimentally characterizing the weld formation over time, and a novel microstructural classification method for the weld region of an ultrasonic metal weld is introduced to complete the weld quality characterization.
References
More filters
Journal ArticleDOI
Simulation and Optimization of the Dual Lithium Ion Insertion Cell
TL;DR: In this article, the galvanostatic charge and discharge of a dual lithium ion insertion (rocking chair) cell are modeled with concentrated solution theory, and the insertion of lithium into and out of active electrode material is simulated using superposition, greatly simplifying the numerical calculations.
Journal ArticleDOI
Characterisation of dissimilar joints in laser welding of steel–kovar, copper–steel and copper–aluminium
T.A. Mai,A.C. Spowage +1 more
TL;DR: In this article, the results of an investigation into laser welding of dissimilar metals without filler materials using a 350 W pulsed Nd:YAG laser are presented, where the mixing behavior of the materials in the fusion zone, the microstructure, the presence of defects, hardness and residual stress of the joints were all investigated.
Journal ArticleDOI
Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process
TL;DR: In this paper, the authors considered control parameter optimisation and surface preparation issues for the production of aluminium alloy 6061 specimens, and showed that the dynamic interfacial stresses, generated under UC conditions, compacted the oxide layer to form brittle, ceramic bonds at the weld interface.
Journal ArticleDOI
Thermomechanical analyses of ultrasonic welding process using thermal and acoustic softening effects
Amir Siddiq,Elaheh Ghassemieh +1 more
TL;DR: In this article, a very first attempt has been made to simulate the ultrasonic welding of metals by taking into account both of these effects (surface and volume) and a phenomenological material model has been proposed which incorporates these two effects (i.e. surface and volume).
Patent
Battery pack with integral cooling and bussing devices
TL;DR: In this paper, a battery module has a plurality of battery heatsink assemblies with the cells disposed therebetween, and rods extend through the each heatsink assembly to secure the heatsink and the cell with one another to form the battery module.