Cell Connection: Impact on Cell Performance due to Contact Resistance for Cylindrical Cell

会议论文
发表日期：

2026年

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Mohd Ibthisham Ardani,
Qurratul Haiqal Mohamad Rozi,
Mohd Farid Mohd Said,
Mohd Azlan Suhaimi,
Zul-Hilmi Che Daud,
Mat Hussin Ab Talib

摘要

In a cylindrical battery pack, the performance and efficiency of individual cells are often affected by contact resistance at connection points. This resistance, which could potentially arise from imperfect interfaces between cells and connectors, leads to energy losses and uneven heat generation, which can compromise overall pack efficiency and cell longevity. This study investigates the impact of contact resistance on cell performance, focusing on key metrics such as discharge capacity, voltage drop and temperature gradient. However, this is limited to a single cell only. Experimental tests were conducted on a standard cylindrical 18650 cells under varied resistance conditions to analyse changes in energy output and power loss. This is conducted by deploying the test by using different cell tab connectors. A flat and a pointed connecter are used, and it represent connector with different contact resistance. Additional resistance on the cell causes significant differences in the voltage curve, which directly impacts the available energy content of the cell and its internal thermal conditions. It shows significant differences in cell performance when different cell tab connectors are used. This work provides practical insights for improving battery pack design and enhancing the reliability and efficiency of cylindrical cells in demanding applications such as electric vehicles and energy storage systems and prepared for future developments in battery technology.