Specialized Solutions for EV Busbars: Introducing the ECCB™ PEM eConnect® Contact Bushing
In the rapidly evolving electric vehicle (EV) sector, the demand for superior electrical connections continues to grow. John O’Brien, Global Technologist at PennEngineering®, sheds light on how the new ECCB™ PEM eConnect® Contact Bushing is revolutionizing busbar applications in electric vehicles.
Meeting Changing Requirements in the EV Sector: Evolution of Electrical Pathways in EVs
Initially, high current pathways in early EVs relied heavily on heavy-duty cables. While these cables offered great flexibility, their performance was limited. As the EV industry advanced, so did the need for higher currents, prompting a shift towards busbars as a more efficient alternative.
Copper Busbars: Benefits and Challenges
Early busbars were made of copper, requiring significant material to meet the EV sector's standards. This not only increased weight but also raised costs. To address this, companies opted to run busbars warmer, reducing the copper needed by half. Over time, busbars could operate at up to 10A/mm², although this caused them to heat up significantly. Fortunately, the cooling systems already necessary for EV batteries could also cool busbars, maintaining their slim profile and reducing both weight and costs.
Transition to Aluminium
By 2022, the rising cost of copper led EV companies to explore alternative materials like aluminium. Despite needing twice the amount of aluminium, its weight was still half that of the copper required, offering both weight and cost savings. However, aluminium posed a challenge due to its rapid formation of an insulating oxide layer, complicating electrical connections.
Introducing the ECCB™ PEM eConnect® Contact Bushing
To overcome these challenges, we developed the ECCB™ PEM eConnect® Contact Bushing. This innovative product ensures reliable electrical connections between aluminium busbars, as well as copper, PCBs, and cable terminals. Its high surface area knurl design pierces the oxide layer on busbars, creating consistent electrical connections without needing to plate the busbar itself.
Designed for installation into straight punched holes without additional surface preparation, the ECCB™ PEM eConnect™ Contact Bushing breaks through aluminium and copper oxide layers for low resistance connections. It is ideal for use in panels with sheet hardness HRB 50 / HB 82 or less.
Installation Solutions
PennEngineering® also offers PEM eConnect™ current-carrying pins, providing superior electrical connections in applications demanding high performance from internal components. Available in self-clinching and broaching mounting styles, these pins are suitable for electric vehicles, including EV charging systems, EV powertrains, EV power distribution, and industrial switchgear.
Proven Performance
The ECCB™ PEM eConnect™ Contact Bushing is already delivering significant benefits for EV companies looking to optimize their vehicles. We have extensive data, including thermal cycling testing and current carrying cycling testing, demonstrating that this product meets the highest standards.
For more information on how our specialized solutions can benefit your EV applications, contact us at PennEngineering®. Let's drive the future of electric vehicles together.
More about the ECCB™ PEM eConnect™ Contact Bushing: https://www.pemnet.com/eu/products/engineering-guides/eccb-pem-econnect-contact-bushing/