Automotive Battery pack

manufacturing a review of
battery to tab Joining
 Abstract
Automotive battery packs used for electromobility applications consist of a large
number of individual battery cells that are interconnected. Interconnection of the
battery cells creates an electrical and mechanical connection, which can be realised
by means of different joining technologies. The present work provides an overview
of interdisciplinary challenges occurring at joints which are exposed to electrical
current with a strong focus on interconnecting batteries for electric cars. It
summarizes common quality criteria for the joining technologies and recombines
those with criteria deduced from an electrical engineering point of view.
 Mechanical challenges

Thermo- mechanical challenges

Interdisciplinarity
of battery pack Electro- thermal challenges

design
Electro – mechanical challenges

Metallurgical challenges

Electrical challenges
Quality Criteria

Electrical and thermal requirements

• Resulting joints should have low electrical resistance with narrow scattering
range
• Thermal input during manufacturing should be as small as possible
• High thermal fatigue resistance of created joints

Material and metallurgical requirements

• Low corrosion risk
• Joining of dissimilar materials
• Adaptability to a variety of surface conditions and materials
• Mechanical requirements
1. strong interconnections
2. Good fatigue and creep resistance
3. Low pre- stress level
4. Avoid mechanical or vibrational damage during joining
• Economic requirements
1. Suitability for mass production
2. Low acquisition costs
3. Good possibility to be stabilised and standardised