Do high voltage battery busbars fail under combined mechanical and electrical loads?

Low Volt. Low Volt. 4. Conclusion The failure behavior of high voltage battery busbars under combined mechanical and electrical loads was experimentally investigated using different indenter geometries. The sharp indenter geometry was the most critical in terms of force and penetration until short circuit.

Does humidity affect the electrical failure of automotive battery busbars?

The electrical failure of automotive battery busbars is not affected by humidity. The conducting copper undergoes large plastic deformation until insulation failure. 1. Introduction Reducing global CO 2 emissions in order to fight climate change is one of the major challenges of the 21th century.

What is the difference between copper and aluminium busbars?

Compared to copper busbars aluminium offers a weight and cost save, but requires an increase in cross-sectional area of ~62%. Hence aluminium busbars need more volume for packaging. The highest conductivity is achieved by high purity aluminium (purity of 99.9 wt% Al and higher) in soft temper.

How much current does a copper busbar need?

The current is an estimated continuous rating and plotted versus the cross-sectional area in mm 2. The gradient of the “straight line fit” shows that 5.9A/mm 2 is a rough estimate for copper busbar size. However, to be on the safe side of this I would initially size at 5A/mm 2 before doing the detailed electrothermal analysis.

Why is a busbar a good thermal conductor?

Busbars are good electrical and hence good thermal conductors. This means they can conduct heat away or to other components. During the thermal runaway of a battery pack the composition of the gas within the enclosure can become more conducive to arcing. Thus increasing the rate of thermal runaway and instigating other mechanisms of failure.

What is a good size for a copper busbar?

The gradient of the “straight line fit” shows that 5.9A/mm 2 is a rough estimate for copper busbar size. However, to be on the safe side of this I would initially size at 5A/mm 2 before doing the detailed electrothermal analysis. An important aspect to consider in all busbar designs is to consider the environment and the materials.