from chemistry to pack
At some point in the development of a battery pack design you need to consider the continuous current rating. Do this for charge and discharge as this then gives you one for the fundamental requirements to determine: Plotting continuous power versus system nominal voltage it is possible to see the voltage/power/current design points. Typically electric … Read more
The anti-shunt tab design is there to enable a better resistance micro spot weld. The busbar for a cylindrical or prismatic cell has to be welded blind. Meaning you can only weld from the topside of the busbar as the cell itself is a sealed system. The anti-shunt tab design shown on the left welded … Read more
for Cell Contacting Systems and Busbars Aluminium busbar products are used in manifold applications in batteries and battery systems due to their favourable structural, physical, and chemical properties. When it comes to cell contacting systems and busbars, electrical (and thermal) conductivity are decisive for balancing component resistance and cross-section to meet the designed space. However, … Read more
What is the optimal busbar joint overlap? It should be noted that the experimentally derived optimum is for plain busbars and does not include a hole for the fixture. Braunovic [3] shows the impact on resistance of the joint overlap. The resistance ratio is the ratio of the resistance measured across the joint divided by … Read more
The Electrical Contact Resistance at a metal to metal contact is primarily governed by: The surface structure can be further described by the surface flatness, surface oxidation and water adsorption. These joints in a battery pack will either be welded or bolted. Initially the easiest to think about is the bolted busbar joint. The bolt … Read more
Whether prototyping or creating busbars for production runs we often want high quality parts and this is where photo etching comes into it’s own. Advanced Chemical Etching take us through the process of photo etching and how this can be used to create high quality aluminium or copper parts. We are concentrating on busbars, but … Read more
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%. Hence aluminium busbars need more volume for packaging. The common grades of aluminum for electrical busbars: 1060 1100 1350 6063 6101 Cross-Sectional Area … Read more
The Lucid Air battery design has single side 21700 busbars. This means the positive (+ve) and negative (-ve) connections to the cells are made on one end of the cell. Lucid Motors The busbars very neatly interlace, connecting the negatives on one group of parallel cells to the positives on the next parallel group of … Read more
The electrical design of the battery pack is associated with fundamental electrical elements. These elements are Busbars, Contactors, Fuses, pre-charge resistors, current sensors, HV (High Voltage) and LV (Low Voltage) Connectors, and wiring harnesses. Busbars are electrically conductive materials that maintain current flow from the cells to the external electrical loads. Aluminum and copper are … Read more