Cell casing design for assembly, disassembly and crash safety

About the Project

In order to meet the UK Net Zero Strategy, automotive manufacturers are adopting electrification in their fleet and the adoption of end-of-life principles.

Battery pack construction uses adhesives to fix multiple cells in place, creating a block of battery modules. The adhesive has several benefits, including thermal conductivity, electrical insulating and creating the necessary structural integrity needed around the battery.

However, this process can be slow, induces an element of stacking error and removes the options for easy disassembly for repair, replace or recycle.

In this project modification of the cell end cap design is to be investigated through FE analysis, prototype build and physical testing with the objective of providing a cell which is self-locating adds structural stiffness to the module and allows easy disassembly for repair or recycling.

This project will investigate new joining approaches for the battery back structure, look to incorporate structural rigidity into the module assembly and achieve a method for disassembly between cell and module.

Funding Notes

Funding Source: EPSRC - IDLA

Sponsor Company: Jaguar Land Rover

Stipend: UKRI standard rate for a full-time PhD over 3.5 years (Annual Stipend of £20780 for 2025-26).