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

WMG, The University of Warwick, Coventry CV4 7AL, UK
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World Electr. Veh. J. 2019, 10(3), 55; https://doi.org/10.3390/wevj10030055
Received: 26 June 2019 / Revised: 11 September 2019 / Accepted: 12 September 2019 / Published: 14 September 2019
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. View Full-Text
Keywords: electric vehicle; thin metal film; ultrasonic metal welding; electrical resistance; temperature rise electric vehicle; thin metal film; ultrasonic metal welding; electrical resistance; temperature rise
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Das, A.; Barai, A.; Masters, I.; Williams, D. Comparison of Tab-To-Busbar Ultrasonic Joints for Electric Vehicle Li-Ion Battery Applications. World Electr. Veh. J. 2019, 10, 55.

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