Busbars are metal bars or rods made of copper, brass or aluminum that are used for grounding and conducting electricity. Electrical busbars can be coated with various materials, such as copper, to provide different conductivity limits and variations. Busbars come in many shapes and sizes which will determine the maximum amount of current the conductors can carry before they degrade.
Today there are as many as 20+ busbars in a battery pack, and that number will increase as packs get larger and/or more powerful, while still keeping the space inside the pack extremely tight. Ultrasonic welding is the preferred joining process for busbars in electric vehicle applications. However, since these more powerful batteries are only capable of fast charging, we will soon see more busbar innovations beyond the battery pack to transfer high power from the charging inlet to the battery and on to other high powered motors and equipment, thereby increasing the demand for innovative ultrasonic welding applications.
In the long run, it is thought that bus bars may be preferred over standard cables for some wiring harnesses in the automotive industry. Rising popularity of electric vehicles, cost-effectiveness, ease of installation, low maintenance and service costs for vehicle buses, and development of charging infrastructure for electric vehicles are some of the key factors for the growth in demand for vehicle buses.