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  • design bars that are wide enough to maximize contact(surface area), just long enough to connect the battery terminals( you don’t want extra material swinging around; risks causing a short), and thick enough to support the amount of current that will be flowing through these batteries[5].

  • brass busbars are sometimes used, but they are much less conductive than copper and the EMS sigma 60 is probably a much better bet

Interesting stuff to read:

https://rogerscorp.com/blog/2018/considerations-for-choosing-the-optimal-busbar-for-your-electric-vehicle-battery-system

https://www.batterypoweronline.com/articles/sorting-busbar-choices-for-electric-vehicle-power-distribution/

https://interplex.com/busbar-guide/

Questions

What is laser welding vs spot welding that we do - lots of websites mentioned laser welding to minimize contact resistance

Sources:

[1] Battery Module Concept Rev 1

[2] Battery Module Concept Rev 2

[3]Battery Module Rev 5

[4]Battery Module Rev 5

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