Busbar

Example

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Use in Lemonergy

Make series/parallel architecture explicit.

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Connected concepts

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Internal resistance

The resistance a cell presents to current, from its foils, electrolyte, interfaces and the reactions themselves. It converts part of the delivered energy into heat, sets the voltage drop under load, and rises as the cell ages; a large automotive cell has about a milliohm, a small cylindrical cell tens.

Laser welding

Joining metal with a focused laser beam, used to seal cans, attach caps and connect busbars to cell terminals. It is fast and precise but sensitive to gaps and reflectivity, so copper joints need special wavelengths or beam shaping.

Series and parallel connection

Cells in series add their voltages; cells in parallel add their capacities and share current. A pack is described as, for example, 96s4p: 96 groups in series, each of 4 cells in parallel. Series strings need balancing; parallel groups self-balance through their shared terminals.

Terminal

The external conductor through which current enters and leaves the cell: the can and cap of a cylindrical cell, two posts on a prismatic cell, or the sealed foil tabs of a pouch cell.

Wire bonding

Connecting each cell terminal to a busbar or collector plate with a thin aluminium wire, often a few hundred micrometres thick, attached ultrasonically at both ends. The wire can be sized to act as a fuse, so a cell that shorts internally is cut off from its parallel neighbours; Tesla’s cylindrical-cell packs are the best-known example.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Extended Kalman filtering for battery management systems of LiPB-based HEV battery packs: Part 2. Modeling and identification

   Gregory L. Plett · Journal of Power Sources · 2004

   Topic background · Battery charge balance, open-circuit voltage, ohmic loss, polarization dynamics and model identification; parameters require cell-specific data.

2. Getting Started with the BQ76925

   Texas Instruments · 2019

   Topic background · A concrete BMS analog front-end example: cell voltage, current, temperature measurement and MCU integration.