Grant: Collaborative Research and Development Grants
University of Windsor
$198,400.00
Development of Thermal Sprayed Battery Cell Terminal Electrical Interconnection.
FY 2019-20
Summary
High energy density, low self-discharge, and portability characteristics of automotive Li-ion battery packs make them an indispensable power source that is broadly used in electric, hybrid or plug-in-hybrid electric vehicles. An automotive battery pack consists of a large number of individual cells that are electrically connected. Making the required electrical joints represents several challenges, including welding of highly conductive and dissimilar materials, connecting foil tabs with relatively thick bus bar, and joining of multiple sheets. The joining of cells has two parts: tab-to-tab joining and tab-to-bus bar joining. The latter is most difficult to implement since it assumes joining dissimilar materials (usually Al tabs and Cu bus bar) of different thicknesses and different physical characteristics. The main electrical requirement for such joints is to have low electrical resistance, since lower electrical resistance at the joint results in low energy loss, low heat generation and subsequently, lower joint temperature increases during charging and discharging. Resistance spot welding (RSW) is the most cost-effective and rapid method for joining cells for a wide range of battery types and sizes, using both direct current inverter closed loop and capacitor discharge power supplies. However, direct application of RSW to joining Al tabs and Cu bus bar is difficult because of forming Al-Cu intermetallic compounds (IMCs), which are brittle and have a high electrical resistance.The overall goal of the project is to develop the RSW-based process for forming an electrical interconnection interface, which is IMC free and has low contact resistance between battery electrodes and bus bar. The developed process should also allow for fabrication of scalable battery cell-to-module systems with the partner Ford Motor Company of Canada and Ford Motor Company in collaboration with the University of Windsor and Dr. Roman Maev. Roman Gr. Maev, University of Windsor, [email protected]
Program
Collaborative Research and Development Grants
Recipient
Location
Ontario, Canada
Recipient Type
Academia
Type
Grant
Source
NSERC's Awards Data
As published
Application id
542542-2019
Name nom
Maev, Roman
Department département
Physics
Organization id
37
Institution établissement
University of Windsor
Province en
Ontario
Province fr
Ontario
Country en
CANADA
Country fr
CANADA
Fiscal year exercice financier
2019
Competition year année de concours
2019
Award amount
198400
Program id
CRDPJ
Program name en
Collaborative Research and Development Grants
Program name fr
Subventions de recherche et développement coopérative
Group en
RESEARCH PARTNERSHIPS
Group fr
PARTENARIATS DE RECHERCHE
Committee code
96
Committee name en
RPP Internal Decision Cttee
Committee name fr
Cté de décision interne - PPR
Area of application code
305
Area of application group en
Energy resources
Area of application group fr
Ressources d'énergie
Area of application en
Energy storage and conversion
Area of application fr
Stockage et transformation de l'énergie
Research subject code
2007
Research subject group en
Materials science and technology
Research subject group fr
Science et technologie des matériaux
Research subject en
Composites
Research subject fr
Matériaux composites
Installment
inst:1 - 1
Partie
1
Nb partie
1
Application title
Development of Thermal Sprayed Battery Cell Terminal Electrical Interconnection.
Keyword
NSERC
Application summary
High energy density, low self-discharge, and portability characteristics of automotive Li-ion battery packs make them an indispensable power source that is broadly used in electric, hybrid or plug-in-hybrid electric vehicles. An automotive battery pack consists of a large number of individual cells that are electrically connected. Making the required electrical joints represents several challenges, including welding of highly conductive and dissimilar materials, connecting foil tabs with relatively thick bus bar, and joining of multiple sheets. The joining of cells has two parts: tab-to-tab joining and tab-to-bus bar joining. The latter is most difficult to implement since it assumes joining dissimilar materials (usually Al tabs and Cu bus bar) of different thicknesses and different physical characteristics. The main electrical requirement for such joints is to have low electrical resistance, since lower electrical resistance at the joint results in low energy loss, low heat generation and subsequently, lower joint temperature increases during charging and discharging. Resistance spot welding (RSW) is the most cost-effective and rapid method for joining cells for a wide range of battery types and sizes, using both direct current inverter closed loop and capacitor discharge power supplies. However, direct application of RSW to joining Al tabs and Cu bus bar is difficult because of forming Al-Cu intermetallic compounds (IMCs), which are brittle and have a high electrical resistance.The overall goal of the project is to develop the RSW-based process for forming an electrical interconnection interface, which is IMC free and has low contact resistance between battery electrodes and bus bar. The developed process should also allow for fabrication of scalable battery cell-to-module systems with the partner Ford Motor Company of Canada and Ford Motor Company in collaboration with the University of Windsor and Dr. Roman Maev. Roman Gr. Maev, University of Windsor, [email protected]
