LITHIUM‐ION BATTERY MANUFACTURING FOR ELECTRIC VEHICLES: A CONTEMPORARY OVERVIEW

Battery electric vehicles (BEVs) fall into one of the following four categories: hybrid electric vehicle (HEV), plug‐in electric vehicle (PHEV), extended range electric vehicle (EREV), and pure BEV. This chapter reviews different formats and structures of Li‐ion battery cells, modules, and packs in BEVs. It focuses on the characteristics relevant to the joining, assembly, and packaging rather than the battery chemistries, functions, and performances. A number of BEV manufactures use pouch cells for lightweighting, better volumetric energy density, and high spatial efficiency. The chapter reviews a few selected joining technologies that are pertinent to Li‐on battery cell and pack manufacturing, that is, ultrasonic welding, resistance welding, laser welding, wire bonding, and mechanical joining. It discusses the advantages and limitations as well as the applications in major BEVs. The chapter also discusses the battery manufacturing processes and particularly the joining processes. The chapter focuses on the manufacturing processes most relevant to BEVs in today's marketplace.