Application of automotive battery system manufacturing connection technology

According to information obtained, automotive battery packs for electric vehicles consist of a large number of individual cells that are structurally fixed and electrically connected. Fabricating the required electrical and structural joints presents several challenges, including joining multiple thin highly conductive/reflective materials of varying thicknesses, potential damage during the joining process (thermal, mechanical, or vibration), high joint durability requirements, and more.

The following describes the applicability of major and emerging connectivity technologies to support the wide range of connectivity requirements present in battery pack manufacturing. It identifies the advantages, disadvantages, limitations, and concerns of connection technologies. The maturity and application potential of current connectivity technologies are mapped against the manufacturing readiness level (MRL) in the market.

Battery packs for electric vehicles and hybrid or plug-in hybrid electric vehicles (EV/HEV/PHEV), experimentally demonstrating the state of the art in emerging connectivity technologies. Among them, battery connections can use a variety of mechanical fastening methods, including nuts and bolts, spring buckles, screws or buckles, etc., which are parts inside the battery; in vehicle connection to the battery, the vehicle and battery are connected through conversion connectors or terminals interconnected.

Battery manufacturers continue to make advancements to improve the safety, weight, cost, size, durability and energy density of battery packs. To meet these requirements, this section focuses on battery types and different connection technologies to reflect the battery pack structure and its connectivity at hierarchical levels (i.e., cell, module and pack level).

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