2024

Vol.31 No.3

Editorial Office

Review

  • Journal of the Microelectronics and Packaging Society
  • Volume 30(2); 2023
  • Article

Review

Journal of the Microelectronics and Packaging Society 2023;30(2):33-42. Published online: Aug, 18, 2023

Battery Module Bonding Technology for Electric Vehicles

  • Junghwan Bang1,†, Shin-Il Kim1,2, Yun-Chan Kim1,2, Dong-Yurl Yu1 , Dongjin Kim1 , Tae-Ik Lee1 , Min-Su Kim1 , and Jiyong Park1
    1 Advanced Joining & Additive Manufacturing R&D Department, Korea Institute of Industrial Technology(KITECH), 156, Gaetbeol-ro, Yeonsu-gu, Incheon 21999, Korea, 2 Department of Material Science and Engineering, Korea University, Seoul, 02841, Korea
Corresponding author E-mail: nova75@kitech.re.kr
Abstract

Throughout all industries, eco-friendliness is being promoted worldwide with focus on suppressing the environmental impact. With recent international environment policies and regulations supported by government, the electric vehicles demand is expected to increase rapidly. Battery system itself perform an essential role in EVs technology that is arranged in cells, modules, and packs, and each of them are connected mechanically and electrically. A multifaceted approach is necessary for battery pack bonding technologies. In this paper, pros and cons of applicable bonding technologies, such as resistance welding, laser and ultrasonic bonding used in constructing electric vehicle battery packs were compared. Each bonding technique has different advantages and limitations. Therefore, several criteria must be considered when determining which bonding technology is suitable for a battery cell. In particular, the shape and production scale of battery cells are seen as important factors in selecting a bonding method. While dealing with the types and components of battery cells, package bonding technologies and general issues, we will review suitable bonding technologies and suggest future directions.

Keywords Battery joining technologies, Electric Vehicle, Battery cell, Battery module, Dissimilar materials

REFERENCES
  • G. M. Jeon, "내연기관자동차와 전기자동차의 공존", Petroleum & Energy, 306, 26-29 (2018).
  • A. Sharif, Y. C. Chan, and R. A. Islam, "Effect of volume ininterfacial reaction between eutectic Sn-Pb solder and Cumetallization in microelectronic packaging", Mater. Sci. Eng., B106, 120 (2004).
  • S. Chu and A. Majumdar, Opportunities and challenges for a sustainable energy future, Nature, 488, 294-303 (2012).
  • A. Das, D. Li, D. Williams, and D. Greenwood, Joining Technologies for Automotive Battery Systems Manufacturing, World Electric Vehicle Journal, 9(2), 22 (2018).
  • M. Sahin, Joining of aluminium and copper materials with friction welding, Journal of Advanced Manufacturing Technology, 49, 527-534 (2010).
  • C. Tan, Z. Jiang, L. Li, Y. Chen, and X. Chen, "Microstructural evolution and mechanical properties of dissimilar Al-Cu joints produced by friction stir welding, Materials & Design, 51, 466-473 (2013).
  • D. S. Buck, R. N. Fattig, and B. J. Silk, "Battery pack with integral cooling and bussing devices", Enerdel, USA, (2008).
  • T. Kawakatsu, T. Fukuoka, K. Tsutsui, I. Katsumata, and Y. Hattori, "Nickel-Metal Hydride Battery for Hybrid Electric Vehicles", Matsushita Technical Journal, 52(4), (2006).
  • T. Matsuoka, K. Matsumoto, H. Takedomi, and Hasegawa, "Charging Element Device And Holding Structure Therefor", Honda Giken Kogyo Kabushiki Kaisha, (2002).
  • M. Pfriem and F. Gauterin, "Development of Real-World Driving Cycles for Battery Electric Vehicles", World Electr. Veh. J., 8, 14-24, (2016).
  • M. Keynes, "Our Guide to Batteries; Johnson Matthey Battery Systems", JMBS, UK, (2015).
  • G. Reinhart, T. Zeilinger, J. Kurfer, M. Westermeier, C. Thiemann, M. Glonegger, M. Wunderer, C. Tammer, M. Schweier, and M. Heinz, "Research and Demonstration Center for the Production of Large-Area Lithium-Ion Cells", Springer, Berlin, Germany, pp. 3-12, (2013).
  • S. Dong, G. Kelkar, and Y. Zhou, "Electrode Sticking During Micro-Resistance Welding of Thin Metal Sheets", IEEE Trans. Electron. Packag. Manuf., 25, 355-361, (2002).
  • G. Shannon, "Battery Welding: Using Lasers for Tab Welding Applications", Amada Miyachi Blog, (2002), http://info.amadamiyachi.com/blog/laser-welding-tabs-for-battery-packmanufacture.
  • X. Sun, "Effect of Projection Height on Projection Collapse and Nugget Formation-A Finite Element Study", Weld. J., 80, 211-216, (2001).
  • G. Shannon, "Applying the Right Technology for Welding Batteries", (2014), Available online: http://weldingdesign.com/operations/selecting-applying-right-technology-welding-batteries?page=3.
  • G. Berdichevsky, K. Kelty, J. Straubel, and E. Toomre, "The Tesla Roadster Battery System", Tesla Motors: Palo Alto, CA, USA, (2006).
  • I. Lum, M. Mayer, and Y. Zhou, "Footprint Study of Ultrasonic Wedge-Bonding with Aluminum Wire on Copper Substrate", J. Electron. Mater., 35, 433-442, (2006).
  • H. Saariluoma, A. Piiroinen, A. Unt, J. Hakanen, T. Rautava, and A. Salminen, "Overview of optical digital measuring challenges and technologies in laser welded components in EV battery module design and manufacturing", Batteries, 6(3), 47, (2020).
  • M. J. Kang, W. S. Choi, and S. H. Kang, "Ultrasonic and Laser Welding Technologies on Al/Cu Dissimilar Materials for the Lithium-Ion Battery Cell or Module Manufacturing", Journal of Welding and Joining, 37(2), 52-59, (2019).
  • M. Park and Y. Hirata, "Research on Generation of Micro-Plasma Arc and Its Power Intensity", Weld. Int., 31, 284-290, (2017).
  • Y. Hirata, "Pulsed Arc Welding", Weld. Int., 17, 98-115 (2003).
  • M. J. Brand, P. A. Schmidt, M. F. Zaeh, and A. Jossen, "Welding techniques for battery cells and resulting electrical contact resistances", J. Energy Storage, 1(1), 7-14 (2015).
  • P. Taheri, S. Hsieh, and M. Bahrami, "Investigating electrical contact resistance losses in lithium-ion battery assemblies for hybrid and electric vehicles", J. Power Sources, 196(15), 6525-6533 (2011).
  • M. F. R. Zwicker, M. Moghadam, W. Zhang, and C. V. Nielsen, "Automotive battery pack manufacturing a review of battery to tab joining", Journal of Advanced Joining Processes 1, 100017, (2020).
  • M. Abbasi, A. K. Taheri, and M. Salehi, "Growth rate of intermetallic compounds in Al/Cu bimetal produced by cold roll welding process", Journal of Alloys and Compounds, 319, 233-241, (2001).
  • E. De Vries, "Mechanics and Mechanisms of Ultrasonic Metal Welding", The Ohio State University, Columbus, OH, USA, (2004).
  • A. Siddiq and E. Ghassemieh, "Thermomechanical Analyses of Ultrasonic Welding Process Using Thermal and Acoustic Softening Effects", Mech. Mater., 40, 982-1000, (2008).
  • T. H. Kim, J. Yum, S. J. Hu, J. P. Spicer, and J. A. Abell, "Process Robustness of Single Lap Ultrasonic Welding of Thin, Dissimilar Materials", CIRP Ann. Manuf. Technol., 60, 17-20, (2011).
  • S. S. Lee, T. H. Kim, S. J. Hu, W. W. Cai, J. A. Abell, and J. Li, "Characterization of Joint Quality in Ultrasonic Welding of Battery Tabs", J. Manuf. Sci. Eng., 135, 021004, (2013).
  • H. T. Fujii, H. Endo, Y. S. Sato, and H. Kokawa, "Interfacial microstructure evolution and weld formation during ultrasonic welding of Al alloy to Cu, Materials Characterization", 139, 233-240, (2018).
  • C. Walsh, "Laser Welding-Literature Review", University of Cambridge, Cambridge, UK, (2002).
  • W. M. Steen and Mazumder, "In Laser Material Processing", J. Laser Welding, Eds., Springer, London, UK, pp. 199-249 (2010).
  • P. Schmalen, P. Plapper, and W. Cai, "Process Robustness of Laser Braze-Welded Al/Cu Connectors", SAE Int, J. Altern, Power, 5, 195-204, (2016).
  • M. J. Brand, P. A. Schmidt, M. F. Zaeh, and A. Jossen, "Welding Techniques for Battery Cells and Resulting Electrical Contact Resistances", J. Energy Storage, 1, 7-14, (2015).
  • Y. Zhou, P. Gorman, W. Tan, and K. J. Ely, "Weldability of Thin Sheet Metals During Small-Scale Resistance Spot Welding Using an Alternating-Current Power Supply", J. Electr. Mater, 29, (2000).
  • G. Shannon, "Improve Tab to Terminal Connections in Battery Pack Manufacturing", Amada Miyachi America Inc., Monrovia, CA, USA, (2016).
  • J. Varis, "Ensuring the Integrity in Clinching Process", J. Mater. Process. Technol, 174, 277-285, (2006).
  • T. Balawender, T. Sadowski, and M. Knec, "Technological Problems and Experimental Investigation of Hybrid: Clinched-Adhesively Bonded Joint", Arch. Metall. Mater., 56, 438-446 (2011).
  • C. S. Kang and J. P. Jung, "Micro-Joining", Samsung books, Seoul, Korea , ISBN 89-88197-51-8, 4, (2004).
  • H. J. Kang, B. G. Baek, and J. P. Jung, "Recent Low Temperature Solder of SnBi and Its Bonding Characteristics", Journal of Welding and Joining, 38(6), 576-583, (2020).
  • J. H. Bang, D. Y. Yu, Y. H. Ko, J. H. Son, H. Nishikawa, and C. W. Lee, "Intermetallic compound growth between Sn-Cu-Cr lead-free solder and Cu substrate", Microelectronics Reliability, 99, 62-73 Contents, (2019).
  • J. H. Bang, D. Y. Yu, M. Yang, Y. H. Ko, J. W. Yoon, H. Nishikawa, and C. W. Lee, "Improvement in Thermomechanical Reliability of Low Cost Sn-Based BGA Interconnects by Cr Addition", Metals, 8, 586, (2018).
  • M. Kamal and El. S. Gouda, "Effect of zinc additions on structure and properties of Sn-Ag eutectic lead-free solder alloy", J. Mater. Sci. Mater. Electron., 19, 81-84, (2008).
  • A. K. Gain, T. Fouzder, Y. C. Chan, and W. K. C. Yung, "Microtructure, kinetic analysis and hardness of Sn-Ag- Cu-1 wt% nano-ZrO2 composite solder on OSP-Cu pads", J. Alloys Compd., 509(7), 3319-3325, (2011).
  • I. E. Anderson, "Development of Sn-Ag-Cu and Sn-Ag- Cu-X alloys for Pb-free electronic solder applications", J. Mater. Sci. Mater. Electron., 18, 55-76, (2007).
  • L. Liu, P. Wu, and W. Zhou, "Effects of Cu on the interfacial reactions between Sn-8Zn-3Bi-xCu solders and Cu substrate", Microelectronics Reliability, 54(1), 259-264, (2014).
  • M. J. Brand, E. I. Kolp, P. Berg, T. Bach, P. Schmidt, and A. Jossen, "Electrical resistances of soldered battery cell connections". J. Energy Storage, 12, 45-54 (2017).
  • M. J. Brand, P. A. Schmidt, M. F. Zaeh, and A. Jossen, "Welding techniques for battery cells and resulting electrical contact resistances", J. Energy Storage, 1(1), 7-14, (2015).
  • P. R. Bonenberger, "The First Snap-Fit Handbook", 3rd ed., Hanser, Munich, Germany, pp. I-XXII, (2016).
  • L. Shui, F. Chen, A. Garg, X. Peng, N. Bao, and J. Zhang, "Design optimization of battery pack enclosure for electric vehicle", Struct. Multidiscip. Optim., 58(1), 331-347, (2018).
  • S. K. Hong, B. Epureanu, and M. Castanier, "Parametric Reduced-Order Models of Battery Pack Vibration Including Structural Variation and Pre-Stress Effects", In SAE 2013 Noise and Vibration Conference and Exhibition, (2013).
  • H. Nishikawa and N. Iwata, "Formation and growth of intermetallic compound layers at the interface during laser soldering using Sn-Ag Cu solder on a Cu Pad", Journal of Materials Processing Technology, 215, 6-11, (2015).
  • H. Nishikawa and S. Kubota, "Impact strength of Sn-58mass%Bi/Cu joints by laser process", European Microelectronics Packaging Conference, September, Friedrichshafen, Germany, (2015).
  • M. Fleckenstein, O. Bohlen, M. A. Roscher, and B. Baker, "Current density and state of charge inhomogeneities in Li-ion battery cells with LiFePO4as cathode material due to temperature gradients", J. Power Sources, 196(10), 4769-4778, (2011).
  • N. Yang, X. Zhang, B. Shang, and G. Li, "Unbalanced discharging and ageing due to temperature differences amongst the cells in a lithium-ion battery pack with parallel combination", J. Power Sources, 306, 733-741, (2016).
  • L. Shui, F. Chen, A. Garg, X. Peng, N. Bao, and J. Zhang, "Design optimization of battery pack enclosure for electric vehicle". Struct. Multidiscip. Optim., 58(1), 331-347, (2018).
  • O. Mokhtari and H. Nishikawa, "Effects of In and Ni Addition on Microstructure of Sn-58Bi Solder Joint", Journal of Electronic Materials, 43(11), (2014).
  • S. S. Lee, T. H. Kim, S. J. Hu, W. Cai, and J. A. Abell, "Joining Technologies for Automotive Li-Ion Battery Manufacturing: A Review", ASME Conference Proceedings (49460). 541-549, (2010).
  • D. Lee and W. Cai, "The effect of horn knurl geometry on battery tab ultrasonic welding quality, 2D finite element simulations", Journal of Manufacturing Processes, 28, 428-441, (2017).
  • R. V. Nanditta and N. B. Rahul, "Review on Comparative Study of Various, Automotive Cell Joining Techniques and Challenges", Proceedings of the International Conference on Electronics and Renewable Systems, (2022).