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Safe and efficent EV cell-to-cell bonding

The rise of electric powertrains has created new joining needs when it comes to battery assembly.  Batteries have become an integrated part of the vehicle structure and EV battery assembly is safety-critical.  This demands smart and secure joining technologies in every step of the production process. 

October 7, 2020

To supply the required energy from the EV battery, lithium-ion prismatic cells must be firmly attached to each other to form cell stacks.  Cell-to-cell bonding presents a major challenge because the cells are sensitive, meaning that no heat or force can be applied in the joining process.

By using two component (2C) adhesive bonding, no external heat is required for hardening, which results in a joint that meets the highest levels of rigidity and crash behaviour. Through the use of light elastic adhesives, vibrations from the moving vehicle are absorbed, which increases the lifetime of the battery. In addition, cell-to-cell bonding also allows the cells to expand slightly when the battery is charging and discharging.

To achieve these advantages, adhesive application needs to be precise and reliable to avoid air pockets and crucially, to ensure full contact and insulation. In the case of a vehicle collision, air pockets in the battery can cause short circuits, which present a major safety issue in high voltage EV power systems. While 2C adhesive bonding is suitable for cell-to-cell joining, the dispensing technology used to apply the bonding must be bubble-free to ensure safety.

As a world-leading provider of bonding and dispensing technologies, Atlas Copco’s range of SCA adhesive dispensing and Quiss vision quality inspection systems enables precise accuracy of application, to avoid air pockets.

Depending on the requirements of the design, Atlas Copco offers one component (1C) and 2C applications.  2C applications are often used for cell-to-cell bonding because no external heat is required for hardening.  In addition, the high metering accuracy and mixing quality of Atlas Copco SCA dispensing systems allows the most advanced 2C requirements to be met, whilst maintaining high speed and process reliability.

With innovative joining technologies and a broad expertise in battery assembly, Atlas Copco is your strategic partner for electromobility.

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