Bachelor's or Master's thesis - Prototype Development of Detachable Cell Contacts for Pouch Cells

Bachelor's or Master's thesis - Prototype Development of Detachable Cell Contacts for Pouch Cells (all genders)DarmstadtAs electric mobility continues to expand globally, the repairability and recyclability of traction batteries are becoming increasingly critical. Current battery modules commonly use welded cell connections, which provide good electrical performance but make maintenance, repair, and recycling difficult: if a single cell becomes defective, the entire module often has to be replaced. At Fraunhofer LBF, we are therefore developing detachable and reusable cell contacting solutions that allow defective cells to be exchanged individually and simplify module disassembly at the end of life.The thesis focuses on the prototype development and experimental validation of an easily detachable cell contacting solution for pouch-cell battery modules. Based on the detachable cell contact concept selected in a previous thesis, a prototype module will be manufactured by additive manufacturing and conventional machining, assembled with the provided cells, and evaluated on the eMAST test bench under vibration and climate conditions as well as in a driving cycle including charging and discharging.The cells, additional components, and the complete test infrastructure are provided in-house. The test results will be analysed with regard to mechanical stability, contact reliability, and functional performance, and will contribute to more maintainable, reusable, and recyclable battery systems.

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Manufacture a prototype using additive manufacturing and conventional machining methods based on the selected detachable cell contact design from the previous thesis Integrate the provided cells and additional required components into the module prototype Prepare and carry out tests on the eMAST vibration test bench in a climate chamber Perform vibration testing under relevant environmental conditions Conduct a driving cycle test including charging and discharging of the prototype Analyse the test results and assess mechanical stability, contact reliability, and functional performance Document the prototype development, test setup, results, and conclusions