Battery Systems Using Adhesively Bonded Cells for Scalable and Serviceable Applications

This paper presents a battery cell joining solution leveraging adhesively bonded lithium-ion cells as a foundation for scalable, serviceable, and recyclable energy storage platforms. The proposed design methodology enables mechanically and electrically functional connections and supports a design concept intended for compatibility with automated manufacturing and future robotic disassembly. A123 26650-format cells were tested using Epo-Tek 430 conductive adhesive, with performance evaluated through ESR and G-force measurement experiments. The results indicate that no measurable change in electrical performance was observed within the resolution of the measurement system, while supporting a design concept intended to improve modularity and serviceability. The proposed system shows potential for further investigation in electric vehicle and industrial energy system applications, although further validation under realistic operating conditions is required.