There doesn't seem to be a definitive DIY solution to connecting the tabs on pouch cells, but quite a few ideas. I come across variations when I read about a pack build, so I'd like to collect the types here as a reference and a place of discussion.
Today I just found out about the "Termifoil" connector. I believe its zinc-plated copper.
ES member flexy mentioned a proposal using copper flat bar with "through bolts" and a paper hole puncher.
https://endless-sphere.com/forums/viewtopic.php?f=10&t=38617&start=75#p762822
Then, ended up using vertical screws that attach a copper top-plate to aluminum square-bars underneath. The aluminum bar is drilled and tapped with threads (the threaded "underbars" could be steel, since the copper does the conducting). The tabs insert from underneath through slots in a non-conductive plate made from the same material as PCB boards, and then the tabs are folded over 90-degrees and compressed between the copper and aluminum.
Th sub-pack shown is 6S with 5P bundles
The aluminum bars above are theeaded, and they could be steel if needed.
Jonescg has done something similar. This pack is 5P bundles, and the cells are arranged in a long "U" shape so the positive and negative terminals are at the same end of a rectangular pack. 12S shown, terminals are at the top of the pic.
https://endless-sphere.com/forums/viewtopic.php?f=31&t=38252&start=425#p1280164
Today I just found out about the "Termifoil" connector. I believe its zinc-plated copper.
ES member flexy mentioned a proposal using copper flat bar with "through bolts" and a paper hole puncher.
https://endless-sphere.com/forums/viewtopic.php?f=10&t=38617&start=75#p762822
Then, ended up using vertical screws that attach a copper top-plate to aluminum square-bars underneath. The aluminum bar is drilled and tapped with threads (the threaded "underbars" could be steel, since the copper does the conducting). The tabs insert from underneath through slots in a non-conductive plate made from the same material as PCB boards, and then the tabs are folded over 90-degrees and compressed between the copper and aluminum.
Th sub-pack shown is 6S with 5P bundles
The aluminum bars above are theeaded, and they could be steel if needed.
Jonescg has done something similar. This pack is 5P bundles, and the cells are arranged in a long "U" shape so the positive and negative terminals are at the same end of a rectangular pack. 12S shown, terminals are at the top of the pic.
https://endless-sphere.com/forums/viewtopic.php?f=31&t=38252&start=425#p1280164