Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.

With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between busbars and battery cell terminals on energy efficiency and thermal behavior. The above parameters if not designed & optimized properly may create a bottleneck in achieving higher performance which cells can deliver but will be restricted because of uneven current distribution, higher heat generation and busbar temperature exceeding the limiting values. This makes busbar a critical component in battery pack design for achieving desired performance as well as reducing safety concerns. This study highlights the importance of optimized busbar design in creating safer, more efficient, and reliable EV battery packs, addressing key thermal and electrical challenges.