The typical thickness specifications for cylindrical cell current collectors range from 0.17 mm up to 0.8mm to meet strict space constraints within battery modules.
Design complexities, assembly efficiencies, space constraints—ENNOVI-CellConnect-Round is designed to overcome them all. We provide it with a thin, tough structure, resulting in an excellent current density spread, which ensures consistent performance and efficient, low-loss energy transfer.
Which Materials Are Used to Achieve These Precise Thicknesses?
Conductive metals such as aluminum (AL1000 Series) are identified as the primary materials used for these current collectors. A nickel plating surface treatment option is available to provide anti-corrosion benefits and support selective plating for reliable welding purposes.
ENNOVI is able to achieve this uniform energy distribution by using our proven, precise, and high-volume manufacturing methods, which ensure that every ENNOVI-CellConnect-Round metal plate has a uniform thickness, even in very large battery connections. We provide it with a thin, tough structure, resulting in an excellent current density spread.
High-precision, high-volume manufacturing methods ensure that every metal plate maintains a uniform thickness across the entire assembly, which is critical to achieving an even and balanced current density spread.
How Does Thickness Impact Electrical and Thermal Performance?
Current collectors are required to support high current densities of <15A/mm² while maintaining temperatures of <60°C with cooling. Precise thickness control and thin, robust structures are directly connected to achieving a uniform distribution of current density, which guarantees consistent performance and super-efficient, low-loss energy transfer.
While EV batteries tend to develop hot spots across conventional collector plates, managing these dynamics with a uniform current density spread prevents hot spots and reduces mechanical stress on individual battery cells, helping batteries perform better, go further, and live longer.
Can Such Thin Current Collectors Support Large-Scale Battery Assemblies?
Despite the thin profiles of the collectors, the cell contacting systems are highly robust and can support large battery assemblies. ENNOVI-CellConnect-Round is tough enough for large current collectors, up to 2.5m long. The current collector sizes range in length from 100mm to 2500mm. It offers the flexibility to create designs for battery modules or new advanced cell-to-pack and cell-to-chassis configurations.
Thanks to precision engineering, CellConnect-Round has uniform collector plates that provide a thin, lightweight, yet robust packaging. Furthermore, it provides sturdy and robust packaging formats for environments with high vibration.
Precision Profiles: Maximizing Power in Minimal Space
Design complexities. Assembly efficiencies. Space constraints. ENNOVI-CellConnect-Round is designed to overcome them all. We provide it with a thin, tough structure, resulting in an excellent current density spread, which ensures consistent performance and efficient, low-loss energy transfer. As CCS designs move from bulky plastic trays to using advanced lamination approaches, battery makers can reduce costs, create thinner CCS, and maintain close tolerances for accommodating larger battery packs.
ENNOVI helps customers to accelerate their battery platform development with customized solutions that address performance, range, integration, and scalability demands to bring robust battery designs to market.
Contact our engineering team today to inquire about your battery requirements, request technical specifications, and discover how our thin current collector solutions can enhance your EV battery’s energy density.