Lithium ion Battery Manufgfacturing

1 LithiumLithium ion Battery Manufacturingion Battery ManufacturingyfgyfgS. Jack S. Jack HuHuDepartment of Mechanical EngineeringDepartment of Mechanical EngineeringTheUniversityofMichiganTheUni versityofMichiganThe University of MichiganThe University of MichiganBackgrounds Backgrounds rechargeable batteriesSmall sized cells for portable di(biltl hAttractiveness of Lithium ion batteriesdevices ( , mobile telephones, notebooks, etc.)Large sized cells for Battery electricvehiclesincludingEVHigh power & energy densityHigh energy efficiency Long cycle durability (>1000 cycles)Llfdi ht(ttelectric vehicles including EV, HEV and PHEVLow self discharge rate (up to ten years)Low toxicitycameraLighter weightcell phonelaptopSmaller sizeEVDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor[ ]1 Hierarchy of Automotive LiHierarchy of Automotive Li I Battery PacksI Battery PacksBattery PackCell LevelModule LevelPack LevelElectrodes to Ta bModule to ModuleCase(Sealing)))

2 Cell to CellDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor2 Assembly Technologies for Battery Modules/PacksAssembly Technologies for Battery Modules/PacksBattery module/pack assembly procedureModule assemblyLoading cells from feeder/containerIti&Assembly actions:Stacking Inspection & Sorting cells Loading Sorting Stacking Inserting( )gcomponentsClamping/Jii JoiningJoiningBattery ModuleConnection between modules & controlPack assemblyLoading & StackingBattery PackDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor3 Cell/pack configurations and Joining MethodsCell/pack configurations and Joining MethodsCell types Lithium ion Batteries Li TecA123GS YUASAC ylindrical Prismatic (container)Prismatic (pouch)LG ChemA123 EnerDelAESJCSS anyoEnerDelAESJ iith d(ildihiljii )Department of Mechanical EngineeringThe University of Michigan, Ann ArborJoining methods ( , welding or mechanical joining)

3 4 Cell/pack configurations and Joining MethodsCell/pack configurations and Joining MethodsImplication to joining methodsCylindrical Prismatic (container)Prismatic (pouch) Very flexible Resistance, laser, ultrasonic welding or mechanical jii Flat tabs & bolted tabs Resistance, laser welding or mechanical joining Much more rigid than pouch type Mostly mechanical joining (ildi )joining(sometimes welding)Bolt joiningWelding Bolt joiningRSWM echanical joiningProjection WeldingWelding Welding `Department of Mechanical EngineeringThe University of Michigan, Ann Arbor5 Joining Technologies in Battery ManufacturingJoining Technologies in Battery ManufacturingUltrasonic weldingSolid state welding Wkllfdi i ilBattery applicationsJoining of electrode layers El t dttbjiiWorks well for dissimilar materials and multiple sheetsGood weld for highly conductive materials(e gCuAl)Electrode to tab joiningTab to tab/ tab to busbar joining (pouch type)Ni tab to Cu foil (M ltilldi)AltabtoAlfoilmaterials ( , Cu, Al)A limitation in joint thicknessSensitivity to product/process variations(Multi layer welding)

4 Al tab to Al foilvariations[ ]Current collector to tabweldingCu Al tab welding (dissimilarmaterials)tab weldingDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor[Bella et al., 2009]6[Patent, US 6641027][AmTech](dissimilar materials)ReManufacturingReManufacturing IssuesIssuesDisassemblyReversible joining methodsLogisticsDepartment of Mechanical EngineeringThe University of Michigan, Ann Arbor7