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Joining Technologies for Automotive Battery Systems Manufacturing

WMG, The University of Warwick, Coventry CV4 7AL, UK
Author to whom correspondence should be addressed.
World Electr. Veh. J. 2018, 9(2), 22;
Received: 13 June 2018 / Revised: 2 July 2018 / Accepted: 3 July 2018 / Published: 5 July 2018
PDF [3492 KB, uploaded 5 July 2018]


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. View Full-Text
Keywords: EV (electric vehicle); thin metal film; electrode; materials; powertrain; joining EV (electric vehicle); thin metal film; electrode; materials; powertrain; joining

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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).

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Das, A.; Li, D.; Williams, D.; Greenwood, D. Joining Technologies for Automotive Battery Systems Manufacturing. World Electr. Veh. J. 2018, 9, 22.

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World Electr. Veh. J. EISSN 2032-6653 Published by MDPI AG, Basel, Switzerland RSS E-Mail Table of Contents Alert
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