IC2 - Cell contacting

In this project, a contribution is made to the sustainable use of battery packs for e-bikes, pedelecs and scooters. Research is being conducted on a solution that will enable the battery pack to be disassembled down to the cell level. This will allow packs with new cells to be reused and defective cells to be recycled.

The main challenge here is the implementation of detachable contacting of the cells. On the one hand, the contact resistance of clamped or plug-in connections depends directly on the normal force on the contact. On the other hand, the differences between the respective contact resistances of the individual cells should be as small as possible. This requires that the respective contact forces also have the smallest possible differences. In addition, an actuator system is required for contacting in order to make or break the contact.

Aim

• Quantifying the influence of boundary conditions such as contact force, surface finish, contact material on contact resistance. Contact resistances of 100 - 150 μΩ, comparable to welded joints, can be achieved in principle.
• Initial conceptual design of the contacting of the cells and actuation by the user on the basis of the boundary conditions.
• Criteria-based solution selection, development and validation of a concept for actuating the contacting mechanism for an exemplary e-bike battery.
• Final demonstration of the function on a physical demonstrator with battery cells.