FKFS Veranstaltungen

2024 Stuttgart International Symposium
on Automotive and Engine Technology

2. - 3. Juli 2024

Session: Poster |

Design of a Battery Pack with detachable Cell Contacting for improved Circular Economy

Philip Müller-Welt, Karlsruher Institut für Technologie (KIT)

The usage of battery systems is an important factor for protecting the environment. However, currently the disassembly, reuse and recycling of the pack are still an issue. Battery cells are usually contacted by welding. This makes it impossible to remove individual cells from the pack. As of now there is already existing knowledge of properties of detachable electrical contacts. However, no approaches exist that allow the use of detachable contacting, considering challenges in battery packs with multiple cells and their design. Disassembly of the pack is the main problem regarding a circular economy compliant design. Detachable cell contacts are one potential solution. The main challenge implementing this solution is to achieve a contact resistance as low and equal as possible. Therefore, the authors present a method that allows the initial design and optimization of a battery pack with a detachable contacting system. The design is based on initial requirements such as necessary contacting forces for individual cells and contact materials. In addition to technical functionality, sustainability and weight, cost-effectiveness will be considered for the evaluation of the individual designs. The best-evaluated concept is then designed and manufactured using rapid prototyping methods. Finally, tests will be conducted with the prototype and the associated actuating system to ensure functionality of the designed pack under different influences such as temperature or vibration.