Cell-Internal Contacting of Prismatic Lithium-Ion Batteries Using Micro-Friction Stir Spot Welding

Sigl, Martina E.; Grabmann, Sophie; Kick, Luca-Felix; Zens, Amanda; Hartl, Roman; Zaeh, Michael F.

doi:10.3390/batteries8100174

Cited by 6 publications

(1 citation statement)

References 29 publications

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“…Therefore, it is essential that the stacked electrodes be contacted, i.e., joined, with an arrester tab. This process is referred to as internal contacting [3,[5][6][7]. Two properties of the joint are crucial in this context.…”

Section: Introductionmentioning

confidence: 99%

Challenges in Contacting Metal–Polymer Current Collectors in Pouch Cells

Gruhn,

Krüger,

Mund

et al. 2023

JMMP

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Recent research focuses on replacing metal current collectors with metallized polymer foils. However, this introduces significant challenges during cell production, as manufacturing steps must be adapted. Currently, copper is used as the current collector on the anode side and aluminum on the cathode side. These current collectors are then joined within the cell with an arrester tab. This step, known as contacting, is carried out industrially in pouch cells using ultrasonic welding or laser beam welding. However, since the polymer foil is electrically insulating, the current contacting procedures cannot be directly transferred to the metal–polymer current collectors. In this work, ultrasonic welding, laser beam welding, and a mechanical contacting method are considered, and the challenges arising from the material properties are highlighted. The properties of the joints are discussed as a function of the number of foils and the coating thickness of the metallization. It is demonstrated that successful contacting by ultrasonic welding and mechanical clamping is possible, as both mechanical strength and electrical conductivity are ensured by the joint. Laser beam welding was unsuccessful. Additionally, the electrical resistance is one to two orders of magnitude higher than that of pure aluminum and copper foils, which necessitates further optimization. Furthermore, ultrasonic welding is limited to welding 16 foils or fewer. This does not match industrial requirements. Consequently, novel approaches for contacting metal–polymer current collectors are required.

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Section: Introductionmentioning

confidence: 99%

Challenges in Contacting Metal–Polymer Current Collectors in Pouch Cells

Gruhn,

Krüger,

Mund

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

A method for the reproducible and accurate determination of electrical resistances based on multi-layer joints in lithium-ion batteries

et al. 2023

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Experimental and modeling approaches for electric vehicle battery safety: a technical review

Long,

Wang,

Kan

2024

Eng. Res. Express

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Driven by the rising number of fire incidents involving Battery Electric Vehicles (BEVs), this work reviews the current state of knowledge in electric vehicle battery safety, focusing on simulation and experiment methodologies. The critical importance of battery safety is emphasized by the potential for thermal runaway and fires due to various factors. These factors include design and manufacturing flaws, excessive current loads, mechanical damage, improper charging practices (overcharging/overdischarging), extreme temperature exposure, and even as-yet unidentified causes. This study provides a comprehensive review of methodologies employed in lithium-ion battery safety modeling and experiment for BEVs. The review includes various aspects. It includes the high voltage battery system in BEVs, battery safety considerations in BEVs, geometry modeling of battery cells, material modeling of battery cells, simulation framework for batteries, cell-level experiment, testing of materials for cell components, and the application of machine learning. Physics-based simulations that accurately predict battery thermal runaway are crucial for guaranteeing the safety and optimizing the performance of BEVs. While Finite Element Analysis (FEA) is a well-established technique for evaluating the crashworthiness of conventional vehicles, its application to BEVs presents several significant challenges. However, limited literature exists on cell-level experiments involving spray and dropping scenarios. Furthermore, additional data on melting points, thermal properties, and porosity is necessary for component-level testing. This work also highlights the need for robust friction and fatigue models, which remain a critical knowledge gap in this field. Finally, the integration of machine learning approaches for constitutive laws and the development of more complex frameworks are essential advancements for future research. This review is expected to provide a guide in simulation and experiment in EV battery safety engineering.

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Cell-Internal Contacting of Prismatic Lithium-Ion Batteries Using Micro-Friction Stir Spot Welding

Cited by 6 publications

References 29 publications

Challenges in Contacting Metal–Polymer Current Collectors in Pouch Cells

Challenges in Contacting Metal–Polymer Current Collectors in Pouch Cells

A method for the reproducible and accurate determination of electrical resistances based on multi-layer joints in lithium-ion batteries

Experimental and modeling approaches for electric vehicle battery safety: a technical review

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