Application of Copper-Aluminum Composite Materials in New Energy Vehicle Power Battery Bus Bars

Copper-aluminum composite materials are fully combined with copper and aluminum materials in a certain proportion or arrangement through cold rolling or explosion welding. Copper-aluminum composite bus bars are made of them and have been increasingly used in power batteries of new energy vehicles, which can reduce contact resistance and cost.

The commonly used types of copper-aluminum composite materials for copper-aluminum composite bus bars include aluminum-sided copper cladding, aluminum-sided partial copper cladding, double-sided copper cladding, and double-sided partial copper cladding. According to the design requirements of the bus bar's current carrying capacity, the thickness ratio of copper and aluminum and the overall width of the composite material also need to be determined. Then the copper-aluminum composite material manufacturers will choose different processing methods, cold rolling or explosion welding, for different copper and aluminum composite types and specifications.

Bus bars made of copper-aluminum composite materials have low resistance in the copper-aluminum bonding surface, strong corrosion resistance, good ductility and molding. In addition, it can also effectively solve the problems of high heat generation and high loss. In new energy vehicles, replacing aluminum bus bars with copper-aluminum composite bus bars can greatly reduce the contact resistance between aluminum bus bars and copper bus bars. So copper-aluminum composite materials with better performance will have broader use prospects than pure aluminum materials in new energy vehicle power battery bus bars in the future.