Manufacturing of CLAD-Based Battery Interconnects for Electric Vehicle Applications

Abstract 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.