Battery Cell-to-Cell Interconnect & Busbar Design Guide

Material Selection: Choosing conductive materials (e.g., copper, aluminum, nickel) for busbars based on current carrying capacity, cost, weight, and weldability/joinability to cell terminals.
Sizing & Geometry: Calculating busbar cross-sectional area to handle continuous and peak currents without excessive voltage drop or overheating. Designing shape for optimal fit, current distribution, and manufacturability.
Attachment Method: Designing for reliable attachment to cell terminals (e.g., laser welding, ultrasonic welding, resistance welding, bolting), considering mechanical strength and electrical resistance of the joint.
Creepage and Clearance: Ensuring adequate electrical insulation distances between conductive parts of opposite polarity to prevent short circuits or arcing, especially under various environmental conditions (humidity, contamination).
Flexibility/Strain Relief: Incorporating features to accommodate cell expansion/contraction during cycling and temperature changes, and to withstand vibration.

3.1 Cell-to-Cell Interconnect Design (Busbars)