## 5 Discussion
### Applications and Limitations  
In this study, three conductor configurations were evaluated: the C0 group as the baseline, the T1 group representing a conventional design, and the T2 group as the optimized structure. Compared with T1, the T2 configuration significantly improves thermal management by increasing both the cross-sectional area and contact area, thereby enhancing the heat dissipation pathway. However, these benefits are accompanied by increased structural complexity and reduced flexibility in internal space utilization. From a manufacturing perspective, the T1 design benefits from mature processes and lower cost, while T2 introduces higher fabrication requirements and associated cost burdens. In terms of reliability, although conventional structures have proven their long-term durability under standard conditions, they tend to fail prematurely under ultra-high current loads. The optimized T2 structure mitigates these risks through reinforcement informed by multiphysics analysis, although its complexity may introduce new reliability considerations. This work establishes a theoretical framework for evaluating key structural parameters that influence the overcurrent tolerance of lithium-ion batteries. The optimized structure demonstrates potential to reduce both conductor resistance and interfacial resistance, which may lower Joule heating, improve energy efficiency, enhance fast-charging performance, and extend cycle life. To support this, a current-thermal structure coupled finite element model was developed to quantify the effects of cross-sectional area and  
Figure 13: Design guideline for current-carrying structure considering dynamic effect of heat generation and heat dissipation. contact area on thermal response under high-current conditions. This approach transcends traditional design practices by incorporating dynamic thermal effects into structural optimization and forms a scalable framework for performance improvement under similar multiphysics environments. The findings are broadly applicable beyond pulse-discharge scenarios. The proposed design is also relevant for systems operating under low-current but thermally sensitive conditions, such as precision electronics or temperature-regulated energy systems. In addition, the model enables predictive evaluation of current-carrying performance and hotspot formation, offering practical guidance for structural optimization in advanced battery systems. In real-world applications, the optimized conductor structure has promising relevance across multiple industries. For electric vehicles, it supports dynamic testing involving frequent acceleration and braking, where pulse current surges are common. In high-power energy storage systems, it facilitates short-duration high-current output for meeting transient power demands. In aerospace applications, it offers robust performance under instantaneous high-load conditions such as rocket ignition or emergency power delivery. In all these contexts, enhanced overcurrent capacity directly improves peak power delivery and system resilience in critical scenarios. However, several limitations remain. This study assumes a constant welding area and uniform welding quality, which diverges from real-world conditions where process variability, porosity, and residual stress introduce randomness into joint behavior [54,55]. These factors can significantly affect thermal resistance and failure probability. Future research should develop dynamic welding zone models that incorporate real-time monitoring and adaptive parameter control. Multiphysics-based optimization frameworks may be expanded to include residual stress, interface morphology, and microstructural evolution. A comparative cost-performance analysis between the traditional and optimized designs is also necessary to assess industrial scalability. In addition, this work was conducted under a single material system to isolate structural effects.