The growing worldwide demand for electric vehicles (EVs) mandates the development of battery recycling technologies to reduce resource constraints and their negative environmental effects. The adhesive bonding employed in the BMW i3 battery modules presents a difficulty that makes recycling and disassembly procedures more difficult. This thesis attempts to solve this issue.

First and foremost, the goal is to create a mechanical assembly process that simplifies disassembly, increases recyclability, and makes repairs easier.EV types, battery technology, and contemporary joining techniques for battery assemblies are all covered in-depth in the first section of this study's literature overview. It looks at different connecting technologies and emphasizes the drawbacks of sticky bonding. A new mechanical assembly of the BMW i3 battery module is described in depth in the methodology part along with the design, calculation, and assembly methods. The mechanical assembly design's efficacy is assessed through the presentation of two situations.Comparing mechanical assembly versus adhesive bonding, the results show that mechanical assembly gives much better ease of disassembly and recycling possibilities.

To further improve the viability of large-scale recycling operations, the novel design exhibits promise for incorporation into automated disassembly systems.In conclusion, a workable way to increase the recyclability and sustainability of the EV sector is to switch from adhesive to mechanical assembly in EV battery modules. The research presented in this thesis adds to the current endeavors to create environmentally sustainable and effective methods for recycling lithium-ion batteries.