Modelling and characterisation of ultrasonic joints for Li-ion batteries to evaluate the impact on electrical resistance and temperature raise

Das, Abhishek; Ashwin, T.R.; Barai, Anup

doi:10.1016/j.est.2019.02.017

Cited by 45 publications

(25 citation statements)

References 31 publications

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“…The Ni layer exists discontinuously by pushing and moving down to the lower part of the weld in the good weld, indicating that there is a metallurgical bond between the foil and the strip. The main purpose of nickel plating is to prevent corrosion and to enhance the weldability of highly conductive materials [18]. This is because nickel has a higher thermal and electrical resistance than copper [19].…”

Section: Cross-section Analysismentioning

confidence: 99%

Ultrasonic Metal Welding of Multilayered Copper Foils to Nickel-Plated Copper Sheet in Lithium-Ion Battery Cell

Shin¹,

Nam

et al. 2021

Metals

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The battery performance of electric vehicles depends on the density and capacity of the battery; thus, the battery cells must be assembled in as many layers as possible. Electric vehicle batteries are typically composed of several cells which form modules connected by busbars, with dozens of modules manufactured as battery packs. The ultrasonic metal welding (UMW) technology is applied to such multilayered foil welding. This study analyzed UMW to ensure the weldability of multilayered Cu foils and a Ni-plated Cu strip in lithium-ion battery cells through various approaches. In UMW, the effect of the alignment on weld production and quality were examined through the energy and mechanical performance of the weld by conducting comparative experiments on the alignment of the horn and anvil. Additionally, the effects of UMW process parameters, such as the welding pressure, amplitude, and welding time, were statistically analyzed. The weldability evaluation and characteristic analysis were performed based on these variables. Furthermore, the cross-sectional shapes and microstructure behavior of the Ni layers were analyzed based on the weld quality.

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Section: Cross-section Analysismentioning

confidence: 99%

Ultrasonic Metal Welding of Multilayered Copper Foils to Nickel-Plated Copper Sheet in Lithium-Ion Battery Cell

Shin¹,

Nam

et al. 2021

Metals

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“…The percentage change in resistance values for varying thicknesses of Al and Cu busbars are shown in Figure 4b. It is worth noting that similar changes in resistance value were obtained from the 2.0 mm Al busbar (i.e., 26.30%) and the 1. electric current, the electrical resistance is expressed as R = ρl/A, where ρ represents the resistivity, l is the length and A is the cross-sectional area [30,35]. Furthermore, Das et al [30] reported detailed theoretical analysis and simulation methodology for electrical and thermal characterisation based on a single tab-to-busbar joint.…”

Section: Joint Electrical Resistance Behaviourmentioning

confidence: 99%

“…An attempt has been made by Brand et al [29] to measure the electrical resistance at the UMW joint and they observed that maximum tensile load corresponded to lower electrical resistance when ultrasonic welding was employed to join two brass (CuZn37) test samples. Additionally, Das et al [30] reported the electrical resistance change and temperature rise at battery tab joints between the Al/Cu[Ni] tab to single Cu busbar assembly. However, extensive electrical and thermal characterisation of ultrasonic welded joints considering different busbar materials with varying thicknesses are missing from the literature.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications

Das

Barai

Masters

et al. 2019

WEVJ

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Recent uptake in the use of lithium-ion battery packs within electric vehicles has drawn significant attention to the selection of busbar material and corresponding thickness, which are usually based on mechanical, electrical and thermal characteristics of the welded joints, material availability and cost. To determine joint behaviour corresponding to critical-to-quality criteria, this study uses one of the widely used joining technologies, ultrasonic metal welding (UMW), to produce tab-to-busbar joints using copper and aluminium busbars of varying thicknesses. Joints for electrical and thermal characterisation were selected based on the satisfactory mechanical strength determined from the T-peel tests. Electrical contact resistance and corresponding temperature rise at the joints were compared for different tab-to-busbar joints by passing current through the joints. The average resistance or temperature increase from the 0.3 mm Al tab was 0.6 times higher than the 0.3 mm Cu[Ni] tab, irrespective of busbar selection.

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“…The impact on the unknown noise is gradually updated but ignored, in which the recursive partial least square method is introduced to identify the battery parameters online to achieve the accurate real-time charged state prediction purpose. And then, the variable variance Kalman filtering method is proposed to update the noise variance in real time in order to reduce the noise interference that results in the inaccurate charged state estimation values [26,[46][47][48]. The optimal unbiased maximum posterior time-varying estimator can be built to correct the noise statistics online, but the time-varying problem of model parameters cannot be solved effectively due to the accumulated calculation effect.…”

Section: Introductionmentioning

confidence: 99%

A novel charged state prediction method of the lithium ion battery packs based on the composite equivalent modeling and improved splice Kalman filtering algorithm

Wang

Fernandez

et al. 2020

Journal of Power Sources

151

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As the unscented Kalman filtering algorithm is sensitive to the battery model and susceptible to the uncertain noise interference, an improved iterate calculation method is proposed to improve the charged state prediction accuracy of the lithium ion battery packs by introducing a novel splice Kalman filtering algorithm with adaptive robust performance. The battery is modeled by composite equivalent modeling and its parameters are identified effectively by investigating the hybrid power pulse test. The sensitivity analysis is carried out for the model parameters to obtain the influence degree on the prediction effect of different factors, providing a basis of the adaptive battery characterization. Subsequently, its implementation process is carried out including model building and adaptive noise correction that are perceived by the iterate charged state calculation. Its experimental results are analyzed and compared with other algorithms through the physical tests. The polarization resistance is obtained as Rp = 16.66 mΩ and capacitance is identified as Cp=13.71 kF. The ohm internal resistance is calculated as Ro = 68.71 mΩ and the charged state has a prediction error of 1.38% with good robustness effect, providing a foundational basis of the power prediction for the lithium ion battery packs.

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Modelling and characterisation of ultrasonic joints for Li-ion batteries to evaluate the impact on electrical resistance and temperature raise

Abstract: Please refer to published version for the most recent bibliographic citation information. If a published version is known of, the repository item page linked to above, will contain details on accessing it.

Cited by 45 publications

References 31 publications

Ultrasonic Metal Welding of Multilayered Copper Foils to Nickel-Plated Copper Sheet in Lithium-Ion Battery Cell

Ultrasonic Metal Welding of Multilayered Copper Foils to Nickel-Plated Copper Sheet in Lithium-Ion Battery Cell

Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications

A novel charged state prediction method of the lithium ion battery packs based on the composite equivalent modeling and improved splice Kalman filtering algorithm

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