New glue-based battery design could cut EV repair costs and boost recycling
Researchers have demonstrated that lithium-ion battery cells can be reliably joined using conductive adhesive instead of traditional welding, maintaining full electrical performance while enabling easier disassembly. The innovation could simplify manufacturing, reduce maintenance downtime, and dramatically improve battery recycling efficiency—key cost drivers for electric vehicle makers and energy storage companies.
Originaltitel: Battery Systems Using Adhesively Bonded Cells for Scalable and Serviceable Applications
<p>This paper presents a battery cell joining solution leveraging adhesively bonded lithium-ion cells as a foundation for scalable, serviceable, and recyclable energy storage platforms. The proposed design methodology enables mechanically and electrically functional connections and supports a design concept intended for compatibility with automated manufacturing and future robotic disassembly. A123 26650-format cells were tested using Epo-Tek 430 conductive adhesive, with performance evaluated through ESR and G-force measurement experiments. The results indicate that no measurable change in electrical performance was observed within the resolution of the measurement system, while supporting a design concept intended to improve modularity and serviceability. The proposed system shows potential for further investigation in electric vehicle and industrial energy system applications, although further validation under realistic operating conditions is required.</p>