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Flexible Copper Busbar
An Insulated Flat Battery Accessories Busbar is a precision-engineered electrical connector made of high-conductivity copper or aluminum, featuring a flat structure and a protective insulating layer. It is widely used in battery systems to connect individual cells or modules, enabling safe and efficient current distribution in high-density energy environments such as EV battery packs and energy storage systems.
Unlike standard busbars, this flat version is optimized for tight space configurations, while the insulation provides shock protection, short-circuit prevention, and environmental resistance, making it ideal for modern high-voltage applications.
The manufacturing process of an insulated flat busbar includes the following steps:
Material Selection: High-purity copper (e.g., T2) or aluminum is chosen for excellent conductivity.
Cutting & Shaping: The conductor is cut and CNC-machined to exact dimensions and hole patterns.
Surface Treatment: Optional tin or silver plating enhances corrosion resistance and conductivity.
Insulation Coating: The busbar is coated with PVC, PE, epoxy resin, or heat-shrink tubing for safety.
Quality Testing: Each unit undergoes electrical resistance, insulation strength, and durability tests.
Our factory supports custom punching, bending, plating, and multilayer insulation upon request.
These busbars play a vital role in modern electrical systems, especially where compact, high-power configurations are required. Main application fields include:
Electric Vehicles (EVs) – High-voltage battery pack interconnects
Energy Storage Systems (ESS) – Modular battery cabinet wiring
Battery Management Systems (BMS) – Voltage sensing and current routing
Industrial Backup Power Systems – UPS and telecom power modules
Smart Grid & Solar Power Integration – Clean energy interfaces
High Conductivity: Delivers stable, low-resistance power transmission
Enhanced Safety: Fully insulated against electric shocks and short circuits
Compact & Flat Design: Optimized for space-constrained assemblies
Customizable: Dimensions, shapes, hole patterns, and insulation types can be tailored
Mechanical Strength: Maintains structure in vibration-prone and high-load environments
Surface Treatment Options: Tin/silver plating for oxidation resistance and conductivity
Effective design depends on electrical, mechanical, and thermal considerations:
Current-Carrying Capacity: Determine busbar cross-section based on amperage load
Voltage Rating: Choose suitable insulation material based on system voltage
Thermal Management: Account for temperature rise due to continuous current
Spacing & Clearance: Ensure safe distances between conductors
Mounting Requirements: Design holes or slots for bolts, sensors, or alignment features
Working closely with our engineering team ensures your busbar meets both performance and regulatory standards.
At G and N Fortune Limited, we provide full customization services:
Size & Shape: Width, thickness, length tailored to your specs
Hole Punching & CNC Bending: Accurate machining for exact fit
Multi-layer Insulation: Options for high voltage isolation
Surface Plating: Tin, nickel, or silver plating to match your application
Performance Testing: All custom busbars are verified through voltage, current, and insulation tests before shipment
As a trusted supplier in precision power connection solutions, G and N Fortune Limited offers:
Over 10 Years of Manufacturing Experience
Advanced CNC & Laser Equipment for Custom Fabrication
Strict Quality Control – ISO Certified, 100% inspection before delivery
Global Delivery – On-time export support with strong supply chain capability
One-on-One Engineering Support – Helping you optimize your busbar design
Flexible MOQ & Fast Lead Time – Supporting startups to large-scale OEMs
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