Durability of electric vehicle battery pack joints

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To address the global concerns regarding climate changes and increase of earth temperature, carbon dioxide emission has to be reduced/removed. A major source of Co2 emission is transportation vehicles, which account for close to 30% of Canada's greenhouse gas emissions. An active method to reduce this significant contribution to global warming is electrification of transportation vehicles. Battery operated vehicles are the cornerstone of automotive electrification. To improve the efficiency and safety of the batteries in electric vehicles, structural durability of them must be maintained. This project studies the requirements for structural soundness of major weld/joints in a typical battery packs. The joints that are considered in this study include battery terminal to battery connection tabs, new lead-free solder joints, and seam weld used on the housing of battery cells and battery packs. Results will be implemented by Stellantis to expand their adaptation of battery electric vehicles.