| Impact of Busbar-Induced Joule Heating on Battery Temperature Rise in Electric Vehicle Batteries |
| Jihye Lee, Sungkoo Lee |
| PHC Valeo R&D Center, 113 Hosandong-ro, Dalseo-gu, Daegu 42709, Korea |
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Received: April 11, 2025; Revised: May 26, 2025 Accepted: June 3, 2025. Published online: July 15, 2025. |
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| ABSTRACT |
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Recent advancements in hybrid electric vehicles (HEVs) have led to increased power demands, encouraging the adoption of liquid cooling systems. While air cooling affects both battery cells and busbars, liquid cooling offers superior thermal performance but primarily targets battery cells, making it less effective for managing heat in busbars. Under high-current conditions, busbars can generate significant Joule heating, increasing local temperatures and potentially causing cell imbalance and thermal degradation. However, many thermal models have traditionally excluded busbars to reduce computational costs, leading to underestimation of localized heating effects. To address this limitation, a three-dimensional electro-thermal model was developed using STAR-CCM + to analyze busbar-induced heating in HEV battery packs. The model was experimentally validated under a 95 A discharge condition, and additional simulations at 70–120 A revealed that busbar heating can raise adjacent cell temperatures by more than 40 °C. Compared to conventional models, the proposed model significantly improved thermal prediction accuracy, reducing the peak temperature error from 2.9 to 0.2% and the temperature gradient error from 18.5 to 11.1%. These findings highlight the importance of considering busbars not just as electrical conductors but also as key thermal sources in battery system design and management. |
| Key Words:
Busbar effect · Joule heating · Hybrid electric vehicle · Thermal management · Battery pack cooling |
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Corresponding Author.
Jihye Lee , Email. 
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