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Impact of Busbar-Induced Joule Heating on Battery Temperature Rise in Electric Vehicle Batteries.

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Title: Impact of Busbar-Induced Joule Heating on Battery Temperature Rise in Electric Vehicle Batteries.
Authors: Lee, Jihye1 (AUTHOR) jihye.lee@vph.com, Lee, Sungkoo1 (AUTHOR)
Source: International Journal of Automotive Technology. Feb2026, Vol. 27 Issue 1, p285-294. 10p.
Subjects: Bus conductors (Electricity), Resistance heating, Electric vehicle batteries, Cooling systems, Hybrid electric vehicles, Temperature control
Abstract: 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. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Automotive Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
An: 191453361
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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Items – Name: Title
  Label: Title
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  Data: Impact of Busbar-Induced Joule Heating on Battery Temperature Rise in Electric Vehicle Batteries.
– Name: Author
  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Lee%2C+Jihye%22">Lee, Jihye</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> jihye.lee@vph.com</i><br /><searchLink fieldCode="AR" term="%22Lee%2C+Sungkoo%22">Lee, Sungkoo</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Automotive+Technology%22">International Journal of Automotive Technology</searchLink>. Feb2026, Vol. 27 Issue 1, p285-294. 10p.
– Name: Subject
  Label: Subjects
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Bus+conductors+%28Electricity%29%22">Bus conductors (Electricity)</searchLink><br /><searchLink fieldCode="DE" term="%22Resistance+heating%22">Resistance heating</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+vehicle+batteries%22">Electric vehicle batteries</searchLink><br /><searchLink fieldCode="DE" term="%22Cooling+systems%22">Cooling systems</searchLink><br /><searchLink fieldCode="DE" term="%22Hybrid+electric+vehicles%22">Hybrid electric vehicles</searchLink><br /><searchLink fieldCode="DE" term="%22Temperature+control%22">Temperature control</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Automotive Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.1007/s12239-025-00307-8
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      – Code: eng
        Text: English
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      Pagination:
        PageCount: 10
        StartPage: 285
    Subjects:
      – SubjectFull: Bus conductors (Electricity)
        Type: general
      – SubjectFull: Resistance heating
        Type: general
      – SubjectFull: Electric vehicle batteries
        Type: general
      – SubjectFull: Cooling systems
        Type: general
      – SubjectFull: Hybrid electric vehicles
        Type: general
      – SubjectFull: Temperature control
        Type: general
    Titles:
      – TitleFull: Impact of Busbar-Induced Joule Heating on Battery Temperature Rise in Electric Vehicle Batteries.
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            NameFull: Lee, Jihye
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            NameFull: Lee, Sungkoo
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            – D: 01
              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
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