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Lithium‐‐ion Batteryy ManufacturingLithiumfgS. Jack HuDepartment of Mechanical EngineeringThe University of Michigan
BackgroundsRechargeable batteriesSmall sized cells for portabled idevices((e.g., mobilebil ttelephones,l hnotebooks, etc.)Large sized cells for batteryelectric vehicles including EVEV,HEV and PHEVcameraAttractiveness of lithium‐ionbatteriesHigh power & energy densityHigh energy efficiencyLong cycle durability ( 1000 cycles)L self‐dischargeLowlf di hratet (up( tot tentyears)Low toxicityLighterweightcell phonelaptopEVSmaller tment of Mechanical EngineeringThe University of Michigan, Ann Arbor1
Hierarchy of Automotive Li‐Li‐I Battery PacksBattery PackCell LevelElectrodes‐to‐TabModule LevelPack ing)Department of Mechanical EngineeringThe University of Michigan, Ann Arbor2
Assembly Technologies for Battery Modules/PacksBattery module/pack assembly procedureModule assemblyLoading cells fromfeeder/containerIInspectionti &Sorting cellsStackinggcomponentsAssembly actions: LoadingSortingStackingInsertingJoiningClamping/J i com/video/?vid 308)Pack assemblyLoading &StackingDepartment of Mechanical EngineeringThe University of Michigan, Ann ArborConnection betweenmodules & controlBatteryPack3
Cell/pack configurations and Joining MethodsCell typesLithium‐ion BatteriesCylindricalPrismatic (container)Prismatic (pouch)GS YUASALi‐TecA123LG ChemSanyoJCSEnerDelAESJ i i methodsJoiningth d (i.e.,(iweldingldi or mechanicalh i l joining)j i i )Department of Mechanical EngineeringThe University of Michigan, Ann Arbor4
Cell/pack configurations and Joining MethodsImplication to joining methodsCylindrical Flat tabs & bolted tabs Resistance, laser weldingor mechanical joiningRSWBolt joiningPrismatic (container) Much more rigid thanpouch type Mostly mechanical joining((sometimesiwelding)ldi )Bolt joiningProjectionWeldingPrismatic (pouch) Very flexible Resistance, laser, ultrasonicwelding or mechanicalj i ijoiningMechanicaljoiningWeldingWeldingWelding Department of Mechanical EngineeringThe University of Michigan, Ann Arbor5
Joining Technologies in Battery ManufacturingUltrasonic weldingBattery applicationsSolid‐state weldingW k wellll forWorksf dissimilardi i ilmaterials and multiple sheetsGood weld for highly conductivematerials (e(e.g.,g Cu,Cu Al)A limitation in joint thicknessSensitivity to product/processvariationsJoining of electrode layersEl t d t t b joiningElectrode‐to‐tabj i iTab‐to‐tab/ tab‐to‐busbar joining(pouch type)Ni tab‐to‐Cu foilAl tab‐to‐Altab to Al foil(M lti l(Multi‐layerwelding)ldi urrent collector‐to‐tab welding[Bella et al., 2009]Department of Mechanical EngineeringThe University of Michigan, Ann Arbor[Patent, US 6641027]Cu‐Al tab welding(dissimilar materials)[AmTech]6
ReManufacturing IssuesDisassemblyReversible joining methodsLogisticsDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor7
Ultrasonic welding Solid‐state welding Wk ll f di i il Battery applications Joining of electrode layers Works we or dissimilar El t d t tbjii materials and multiple sheets Good weld for highly conductive materials (e g Cu Al) Electrode‐o‐tab joining Tab‐to‐tab/ tab‐to‐busbar joining (pouch type)
