Battery is the heart of an Electric Vehicle. However, it is the battery that comprises the most precious technology of an EV.
High-power EV battery is a combination of cells in series or parallel to achieve voltage ratings approaching 400V. The demand of connecting individual cells of about 1.5 to 2.0V requires a material good at both conducting and insulating rather than typically insulated cables.
And that effective material called BUSBAR – an electric conductor and ground plane separated by an insulator.
The conventional cell connections (welded wires, strips, or lugs) are susceptible to failure when the cells even slightly dislocate during operation, for example, due to the vibration of a moving vehicle. That is why new interconnection techniques using different busbar solutions have been introduced to overcome these challenges, especially for cylindrical cells.
We could summarize the main benefits of BUSBAR over traditional insulated cables as follows:
♦ Handle high current coming from the cells
♦ Increase voltage levels as cells of the future will be up to 5.0 V per cell
♦ Create an effective and necessary clearance and creepage distance for the electrical insulation
♦ Must be durable during the lifetime of battery, capable of withstanding high levels of vibration
♦ Providing rigidly to keep the integrity of battery module assembly
♦ Being flexible enough to cope with elastic, thermal, and G-forces
THERMAL MANAGEMENT CAPACITY
♦ Reduce electrical loss that generates heat at connection points along with connector – busbar
♦ Assist thermal management task and connections either from the top and bottom in both airbase and liquid coolant based cooling system
♦ Electrical cell connection is an essential element of the battery pack design and the selection of the busbar for the battery call is not always as simple as one might think.
Contact us for FREE CONSULTANT and further information about battery module solutions as well as busbar customization service.
Pros Technology – Specialty materials & dispensing solutions.
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