Abstract
An automotive battery pack for use in electric vehicles consists of a large number of individual battery cells that are structurally held and electrically connected. Making the required electrical and structural joints represents several challenges, including, joining of multiple and thin highly conductive/reflective materials of varying thicknesses, potential damage (thermal, mechanical, or vibrational) during joining, a high joint durability requirement, and so on. This paper reviews the applicability of major and emerging joining techniques to support the wide range of joining requirements that exist during battery pack manufacturing. It identifies the advantages, disadvantages, limitations, and concerns of the joining technologies. The maturity and application potential of current joining technologies are mapped with respect to manufacturing readiness levels (MRLs). Further, a Pugh matrix is used to evaluate suitable joining candidates for cylindrical, pouch, and prismatic cells by addressing the aforementioned challenges. Combining Pugh matrix scores, MRLs, and application domains, this paper identifies the potential direction of automotive battery pack joining.
Highlights
Recent advances in developing secondary batteries enables their extensive use in everyday life, from portable technologies to high energy applications
This paper focuses on the applicability of joining technologies for automotive battery system manufacturing
It identifies and reviews suitable joining technologies based on battery pack construction and connectivity requirements for the dominant cell types in use
Summary
Recent advances in developing secondary batteries enables their extensive use in everyday life, from portable technologies to high energy applications. Lithium-ion based secondary batteries show enormous potential to be used for low to high capacity applications, such as portable electronics and electric vehicles, respectively. Low self-discharge, and portability characteristics of Li-ion based automotive battery packs make them an emerging alternative power source that are being increasingly used in electric vehicles (EVs), hybrid or plug-in hybrid electric vehicles (HEVs or PHEVs) [1,2,3]. Often, these vehicles are exposed to different driving conditions having a huge impact on the energy consumption [4]. With a comprehensive and provides guidance for appropriate joining method selection
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