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<p>CLAD<sup>®</sup> materials were explored in this work as an alternative to conventional nickel tabs for battery interconnects in electric vehicle (EV) packs. Roll-bonded copper–stainless steel multi-layer sheets were cut and formed into interconnect geometries, then joined to cylindrical 21700 lithium-ion cells through resistance and laser welding. Trial builds showed no layer delamination, satisfactory bond quality, and stable weld formation across repeated cycles. Comparative thermal modelling indicates a substantial peak-temperature reduction relative to nickel. These findings collectively support adopting CLAD<sup>®</sup> interconnects as a drop-in replacement for nickel tabs, with benefits in electrical efficiency, thermal management, and cost.</p>

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Manufacturing of CLAD-Based Battery Interconnects for Electric Vehicle Applications

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月1日

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  • Toushif Asundi,
  • Prashant P. Date,
  • V. Ramalingeswara Rao

摘要

CLAD® materials were explored in this work as an alternative to conventional nickel tabs for battery interconnects in electric vehicle (EV) packs. Roll-bonded copper–stainless steel multi-layer sheets were cut and formed into interconnect geometries, then joined to cylindrical 21700 lithium-ion cells through resistance and laser welding. Trial builds showed no layer delamination, satisfactory bond quality, and stable weld formation across repeated cycles. Comparative thermal modelling indicates a substantial peak-temperature reduction relative to nickel. These findings collectively support adopting CLAD® interconnects as a drop-in replacement for nickel tabs, with benefits in electrical efficiency, thermal management, and cost.