Adhesive bonding in automotive battery pack manufacturing and dismantling: a review
V. C. Rodrigues, Mohammad Mehdi Kasaei, Eduardo A. S. Marques, Ricardo J. C. Carbas, Lucas F. M. da Silva
Abstract
Abstract The integration of electric vehicles (EVs) powered by lithium-ion batteries (LIBs) marks a pivotal phase towards achieving a net-zero environment. The anticipated surge in EV adoption is expected to yield a substantial influx of battery waste in the coming decade. Despite manifold advancements in optimizing Li-ion battery packs, ensuring a sustainable end-of-life strategy still remains an engineering and economic challenge. The diverse pack configurations further complicate efficient disassembly processes. Adhesives play an essential role in mechanical, electrical and thermal management in battery packs, being suitable for cell-to-cell bonding, busbar protection, cooling plate thermal management and sealing. The spectrum of adhesives used encompasses structural, semi-structural, flexible and pressure sensitive, selected based on component operational specifications throughout the service life. This review provides a comprehensive overview of bonding solutions used in commercial EV energy storage systems, with a focus on the feasibility of dismountable adhesives. It scrutinizes the use of adhesives to bond battery pack components, considering the emerging debonding-on-demand trends. Studies assessing adhesive debonding have demonstrated that some formulations are responsive to external stimuli, capable of weakening the adhesive layer or the interface bond. For battery applications, these modified adhesives must neither show property degradation nor experience such trigger mechanics during service, enabling intentional weakening of the adhesive layer when required. Additionally, this article presents concise solutions for adhesive selection in battery packs, drawing from an in-depth analysis of battery assembly and dismantling processes.