Electrical cell connection is an essential element of the battery module design and the selection of the busbar material and joining approach of cells is crucial to guarantee performance, and safe and reliable operation of the EV battery pack in the vehicle over its entire lifetime. In the Horizon2020 project “Helios”, co-funded by the European Commission, we are developing a “hybrid” modular EV battery pack suitable for different applications, using on one side High-Energy modules with prismatic cells and the other side High-Power modules with pouch cells. In our R&D project, we are exploring some innovative approaches using copper

in the busbar cell connections in both types of modules due to its benefits regarding mechanical, electrical, and thermal high performance. Key issues to consider are mechanical strength (also during vibrations etc.), reliable connections over time, high conductivity and low risk of galvanic corrosion in electrical connections, ease of assembly/ laser welding and disassembly (for maintenance and 2nd life usage), reduced electrical losses and assist the thermal management of the module/ battery pack. Besides the busbar cell tab connections presented here, This presentation will also show an innovative new approach using copper mesh in combination with PCM to enhance the thermal management of temperature peaks (e.g. during super-fast charging).

Hear about:

• Innovative solutions in copper for cell tab connection and in thermal management of EV battery packs
• Copper materials to meet demanding requirements in mechanical performance, compactness, electrical and thermal performance in EVs
• Easier assembly and laser welding to connect cell tab materials and easier disassembly of battery modules for 2nd life usage
• New approach in the absorption of temperature peaks in pouch cells using copper mesh