Battery Cell-to-Cell Connections

Precision Copper Connections for Battery Modules

Battery cell-to-cell connections are fundamental to battery module performance. They must carry high continuous current, tolerate vibration, accommodate thermal expansion, and maintain low resistance over long service lives.

Tranect designs and manufactures copper cell interconnections engineered for electrical reliability, mechanical durability, and scalable production.

Whether the requirement is prototype development or volume manufacture, we support projects from design clarification through to production delivery.

Why Cell-to-Cell Design Matters

Battery module interconnects are not just conductors. They must:

• Carry high DC currents with minimal resistive loss

• Maintain stable contact resistance over thousands of thermal cycles

• Withstand vibration and mechanical shock

• Manage differential expansion between cells and busbars

• Integrate with automated assembly processes

Poorly specified connections increase heat generation, accelerate degradation, and introduce reliability risk. Good design eliminates these problems early.

Our Capabilities

Laminated Copper Cell Links

For higher current density and compact module layouts, we manufacture laminated copper interconnects that offer:

• Controlled flexibility to absorb expansion

• Reduced mechanical stress on cell terminals

• Optimised current distribution

• Improved thermal performance

Available with:

• Insulation films (polyester, Kapton, etc.)

• Custom hole patterns and tolerances

• Tin or nickel plating

• Precision CNC machining or press tooling

Flexible Copper Braided Links

Where vibration or movement is significant, braided copper links provide mechanical compliance while maintaining high conductivity.

We supply:

• Tinned copper braids

• Pressed palm terminations

• Custom widths and cross-sectional areas

• Insulated or bare assemblies

These are particularly suitable for EV modules, energy storage systems, and high-vibration environments.

Solid Copper Busbar Links

For rigid module architectures, we manufacture:

• CNC-machined copper links

• Pressed and formed busbars

• Drilled and countersunk terminations

• Plated components ready for assembly

Manufactured in C101 and C110 copper grades as standard.

Engineering Support

We do not simply supply copper strip cut to shape.

We work with customers to clarify:

• Required continuous and peak current (default design assumption: 2 A/mm² unless otherwise specified)

• Allowable temperature rise

• Connection method (bolted, welded, riveted, brazed)

• Assembly tolerances

• Expected service environment

Where drawings are incomplete, we assist in defining manufacturable solutions that reduce cost and improve robustness.

Early engagement typically reduces redesign cycles and avoids expensive late-stage tooling changes.

Manufacturing Approach

We combine:

• CNC machining

• Press braking and forming

• Laminating

• Riveting and joining

• Plating coordination

This allows us to produce both prototype quantities and scalable production runs without transferring the project between multiple suppliers.

Applications

Our cell-to-cell connections are used in:

• EV battery modules

• Energy storage systems (ESS)

• Hybrid power systems

• Industrial battery packs

• Backup power installations

Quality and Reliability

Electrical connections in battery systems are safety-critical. We manufacture to controlled tolerances and provide:

• Material certification

• Dimensional inspection

• Plating verification

• Repeatable production processes

Consistency matters more than marketing claims.

Let’s Discuss Your Battery Module

If you are developing a new battery system or improving an existing module design, we can support from concept through to production.

Send us:

• Current requirements

• Outline drawings or CAD files

• Target volumes

• Project timelines

We will review and propose a manufacturable solution.