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The final stage of EV battery production is pack assembly. Battery packs of different sizes can be made by including different numbers of modules. Battery pack designs for EVs are complex and vary widely by manufacturer. Figure 56 shows a Chevrolet Bolt battery pack, which uses NMC chemistry in pouch type format.315 A July 2018 article316 describes the design of the Bolt’s battery pack as follows: “The Bolt pack assembly consists of a strong steel underside casing and cross members and a fiberglass or composite top cover, attached with bolts and sealed along its complete perimeter. The Battery Management System (BMS) controller is mounted inside the pack enclosure on top and at the rear...The cell BMS is connected to the controller via a set of wire harnesses. Power relays are the only other devices inside the pack. Unlike the Model 3, the other high-voltage units, high- voltage controller, and DC–DC converters are separate and mounted in other areas of the vehicle. When looking down on the pack as it is mounted in the car, pouch cells are oriented like books on a bookshelf, in groups. The pack consists of ten modules, two in a row. The modules on the bottom are labelled and divided into eight 5.94 kWh modules and two upper 4.75 kWh modules, for a labelled total of 57.02 kWh. Each module is composed of 3p (three in parallel) pouch cells contained in its own metal enclosure, like a book with pages. Eight of the modules contain ten 3p books, and two modulescontain eight3p,foratotalof96s,3p. The pack consists of pouch cells, flat like a sheet of paper but thicker, like cardboard, housed three inside their own metal mechanical box assembly like a book. The pouch books are stacked to make modules like rows of books in a bookshelf. The 3p pouch boxes are held together at the ends by long bolts. The pack thermal management is regulated by sensing temperature via thermistors located at the ends of the modules. There are liquid coolant channels at the base of the pack. There are also metal sheets extending between the 3p pouch books. The vertical cooling plates are attached to the horizontal base cooling plate. The pack has a stacked module arrangement at the rear. The rear of the pack stacks modules on top, giving it the look of pillows on a bed. The upper shelf has its own base cooling plate attached withhoses totheliquidcoolantloopandlowerbasecoolingplate.” 315 Arcus, C. 8 July 2018. “Tesla Model 3 & Chevy Bolt Battery Packs Examined.”PDF Image | Reuse and Recycling of Batteries Employed in Electric Vehicles
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