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Orientador(es)
Resumo(s)
Reliable and efficient busbar connections are critical for electric vehicle battery performance, yet conventional
joining methods struggle with joining dissimilar materials such as copper and aluminum. This paper investigates
a novel solution for joining hybrid copper-aluminum busbars using a technique called hole hemming, which
eliminates the need for heating or additional elements. The focus is placed on the thermal-electrical performance
of hole-hemming joints. Two configurations are studied: joints with and without branches. Numerical models
analyse how sheet thickness affects temperature, electric current density, electric potential, and resistance,
including models with cantered holes to study hole inclusion effects. Experimental tests are conducted on ma
terial strips and unit cells to assess electrical resistance changes with temperature and the effect of Joule heating
on joint configurations. Compression using a hydraulic press is applied to improve contact, leading to significant
electrical resistance improvements (78 % reduction for branched joints and 36 % for branchless ones). Me
chanical shear tests before and after compression show a peak shear load of 4.54 kN and 13.84 mm displacement
for branched joints, with slightly lower values for branchless joints. Despite a minor decrease in mechanical
performance after compression, the improved thermal-electrical performance of the joints outweighs this. The
findings highlight the promising potential of hole-hemmed joints for enhancing hybrid busbar connections.
Descrição
Palavras-chave
Electric vehicle batteries Hybrid busbars Hole hemmed joints Thermal-electrical analysis Electrical resistance
Contexto Educativo
Citação
da Costa, D. P. M., Bragança, I. M. F., Kasaei, M. M., da Silva, L. F. M., & Carbas, R. J. C. (2025). Thermal-electrical analysis of a novel interconnection for hybrid busbars in electric vehicle batteries. Energy, 329, 136629. https://doi.org/10.1016/j.energy.2025.136629
Editora
Elsevier