The conductivity of the aluminum busbar depends on the alloy and the temperature. The conductivity of pure aluminum is approximately 65.0% of IACS (International Annealed Copper Standard). Aluminum has 62% the conductivity of copper, which normally leads engineers to disregard aluminum as a viable conductor for busbar trunking systems.
Today, busbars are already proving to be valuable as battery interconnects, linking the short distances between battery cell modules in modern EVs. As busbars expand beyond the battery, OEMs must weigh design decisions in the context of their full electrical/electronic architectures.
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.
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.
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.
Aluminum Bus Bar Ampacity Table Aluminum Bus Bar Amperes for 6101-T61 Alloy 57% IACS Conductivity Chart Below Bar Sizes (Inches) 1 Bar 2 Bars 3 Bars 4 Bars Ampacities in the table below are for bus bars having an emissivity of 0.4. ... Ampacities and Mechanical Properties of Rectangular Copper ... 60-Hz Ampacity,* Amp Ampacity Charts .
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