The advantages brought by hairpin motors are making electric vehicles more competitive not only with previous generations of EVs, but also with combustion engines. They are more efficient, have a higher power density and thermal performance, and are simpler to manufacture.
Electric vehicle battery packs have complex requirements since they need to withstand large temperature ranges and vibrations. In this article, we will explore the complexities of EV battery manufacturing technologies.
EV batteries are composed of cells, and there are many types of cells. In this article, we will break them down in categories and go over the most important types. We will also discuss possible future cell types and how they can change the automotive industry.
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.
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.
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.
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 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 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, 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.
