Nan Ou lithium battery copper busbar power connector

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.

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.

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.

A battery bus bar is a custom-fabricated component that electrically inter-connects a range of battery cells. You'll find our battery connectors in various applications, from hybrid and electric vehicles to your local central telephone office, in nearly every aspect of our lives. They help keep electricity flowing.

These should be a physical clip that is designed for the life of the pack and considers all of the above points and all environmental inputs. Busbars are good electrical and hence good thermal conductors. This means they can conduct heat away or to other components.

Normally made from copper or aluminium. Careful consideration needs to be taken: Electrical grade aluminum busbar material also known as ec grade aluminum busbar. Compared to copper busbars aluminium offers a weight and cost save, but requires an increase in cross-sectional area of ~62%.