1 Introduction
2 State-of-the-Art/Literature Review
3 Analysis of a State-of-the-Art Battery System
4 Remanufacturing Challenges and Design Modifications
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welded electrical connections between cells and welded busbars are hard to separate without removal of material (such as drilling or milling of the contacts)
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adhesive isolation between the cells and between cell blocks and the cooling plate makes it very difficult to loosen and separate the cells without damaging them
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the cells must not be harmed in any way (e.g. by penetration or destruction of the outer case, short circuits and deformation due to excessive pressure)
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in order to exchange an individual cell in the module frame, the compression within in the block should be maintained as the cells expanded during usage
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the overall SOH within a block should be balanced, which is why the inserted cells’ SOH should fit the SOH of remaining cells
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corrosion, distortion due to thermal and mechanical loads, altered tolerance chains and thereby induced residual stresses complicate the dismantling
State-of-the-art | Design modification approaches |
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Thermal glue for heat dissipation | Function integration of cooling channels and/or isolation in the housing of cells, modules or packs |
Adhesive gap fillers | Alternative materials such as thermal elastomers with lower adhesion characteristics [20] |
Double-sided adhesive film to connect cells | Single-sided adhesive film easier to separate |
insert cells in a plug system/frame for grouping [21] | |
CMB with welded connection to ladder rail | Function integration of sensors in the housing of cells, modules or packs |
Poor accessibility of components which need to be disassembled | Provide space, gaps or edges to level up a component or to ensure the accessibility of components |
Exchange cells without removing the modules if accessibility is given | |
Welded electric contacts are not detachable | Cable plugs for wiring sensors and cable harnesses |
Laser bonding or micro-clinching are detachable [22] |