Batteries & EVs

Prismatic Cells vs. Cylindrical Cells: What is the Difference?
By Stéphane Melançon on April 25, 2022

There are three main types of lithium-ion batteries: cylindrical cells, prismatic cells, and pouch cells. In the EV industry, the most promising developments revolve around cylindrical and prismatic cells.

EV Battery Pack Designs: An Overview
By Stéphane Melançon on April 25, 2022

A well-designed battery pack needs to compete with petrol-based engines when it comes to performance. That’s a real challenge because electric batteries need to overcome complex problems that internal combustion engines do not have.

EV Battery Cooling: Challenges and Solutions
By Stéphane Melançon on April 02, 2022

Today’s technology allows a more efficient use and control of the thermal energy in electric cars. Temperature management is optimized between components such as the battery, the HVAC system, the electric motor, and the inverter. This is done using what is called a Battery Thermal Management System.

Battery Tab Welding Methods
By Stéphane Melançon on February 17, 2022

Different welding methods are used to make all the necessary tab-to-terminal connections (foil-to-tab, tab-to-busbar, etc.) These methods include ultrasonic bonding, laser welding, resistance welding, and micro TIG welding. Whether one method is better suited than another depends on the requirements, such as the combination of materials and the tab thickness.

Structural Batteries: The Cars of the Future Are Glued
By Stéphane Melançon on January 26, 2022

Structural batteries are changing the way electric cars are assembled. Structural adhesives are replacing screws and welds to “glue” components together using a process called adhesive bonding. This process requires additional surface preparation and creates new challenges for automakers and battery makers

Pouch Cell Assembly: New Methods to Improve Manufacturing
By Stéphane Melançon on January 13, 2022

Pouch cells are the first choice for many manufacturers because of their high energy density, great power performances and other design advantages. While they are widely used in electric vehicles, automotive OEMs have strong opinions about whether they should be used.

Ultrasonic Bonding: How it Works & Applications
By Stéphane Melançon on December 22, 2021

Ultrasonic bonding, or ultrasonic welding, is an industrial welding process that uses ultrasonic vibrations to join plastics, metals, or dissimilar materials together. During welding, the joined materials are typically held together by a fixture and a sonotrode.