High-Integrity busbars for electric vehicle battery systems

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ISCF
ISCF
ISCF
ISCF
ISCF

£1,258,105

July 31, 2021

July 31, 2022

Reliable electric and low emission vehicles are key to the UK meeting its Net Zero transport goals, and their rapid development is particularly pertinent given the Government's recent announcement to bring forward the ban of new petrol and diesel cars to 2030\. By investing in innovative battery technologies, the Faraday Battery Challenge will directly enable this transition.

Our project focusses on busbars, which are battery pack or module power distributors, essential for driving propulsion in electric vehicles with additional charging station and energy storage applications. Leading busbar supplier HV Wooding Ltd will partner with experts in materials, automation, manufacturing and testing from The University of Sheffield to improve and standardise the manufacture of insulated busbars. This will result in a high-integrity product capable of meeting higher voltage requirements for battery module assembly and operation.

Epoxy powder is the preferred busbar insulation method, having superior chemical, corrosion and heat resistance, along with excellent electrical insulating properties. It also makes the busbar less susceptible to in-service mechanical challenges in automotive, rail, and aerospace applications including flexing, shock, or vibration. High-integrity epoxy powder coated busbars will facilitate a move towards compact battery designs due to superior dielectric performance, and are easily re-used and recycled to reduce environmental impact.

The project will improve and upgrade the powder coating process with advanced fluidised and spraying methods followed by a standardised test procedure for quality assurance. This is something severely lacking across the industry, with high product fallout rates through defects causing tension between manufacturers and customers. This standardisation is critical for the UK to maintain and grow its competitiveness within this fast growing market. The project will also investigate automation options to increase volume production in line with future demand.