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Solid Copper Busbar
A Copper Busbar for Battery Pack is a precision-engineered electrical component designed to connect cells, modules, and battery management systems (BMS) within lithium-ion, EV, and energy storage battery packs. These busbars provide ultra-low resistance, high conductivity, and reliable thermal performance, ensuring minimal voltage drop and efficient current flow. Variants include Solid Copper Busbar for Battery Pack, Flexible Copper Busbar for Battery Pack, Tinned Copper Busbar for Battery Pack, and Insulated Copper Busbar for Battery Pack. Custom configurations are also available as Custom Copper Busbar for Battery Pack to meet specific design and assembly requirements.
The production of a Battery Pack Copper Busbar involves:
Material Selection: Using T2 pure copper (≥99.9%) for optimal conductivity and current handling.
Forming Process: Copper is processed into solid, laminated, or flexible strips via CNC machining, stamping, or lamination. Flexible busbars may be braided or laminated to accommodate vibration-sensitive or tight installation environments.
Surface Treatment: Busbars can be plated with tin, nickel, or silver to enhance corrosion resistance, improve weldability, or optimize bolted connections.
Customization: Hole patterns, bends, thickness, and width are tailored to match the battery pack design for seamless integration.
Testing: Each busbar undergoes rigorous testing for electrical conductivity, mechanical strength, and thermal performance before delivery.
High Electrical Conductivity: Ultra-pure T2 copper ensures minimal voltage drop, critical for EV and high-load battery systems.
Custom Fit: Support for custom hole patterns, bends, lengths, and plating for fast and precise assembly.
Multiple Surface Finishing Options: Bare copper, tin-plated, nickel-plated, or silver-plated for corrosion resistance and optimized connectivity.
Thermal and Mechanical Stability: Withstands high currents, thermal cycling, and mechanical stress without deformation.
Versatile Form Options: Solid, laminated, or flexible copper busbars to suit both rigid and vibration-sensitive battery applications.
OEM/ODM Service: In-house CNC machining, prototyping, quality inspection, and logistics for turnkey solutions.
T2 Pure Copper (≥99.9%) – Maximum conductivity and reliability.
Tin-Plated Copper – Anti-oxidation, improved weldability.
Nickel-Plated Copper – Corrosion-resistant for high-temperature or harsh environments.
Flexible Copper Laminates – For vibration-prone or compact installations.
| Parameter | Specification |
|---|---|
| Material | T2 Pure Copper (≥99.9%) |
| Type | Solid, Laminated, Flexible |
| Cross-section Size | 10 mm² – 3000 mm² (customizable) |
| Thickness | 1 mm – 10 mm |
| Width | 5 mm – 50 mm |
| Length | Up to 1000 mm |
| Surface Finish | Bare, Tin-plated, Nickel-plated, Silver-plated |
| Insulation Option | Heat shrink tubing, Epoxy coating, PET layer (optional) |
| Voltage Rating | Up to 1000V DC |
| Current Rating | 50A – 1000A (depending on design) |
| Operating Temperature | -40°C to +125°C |
| Tensile Strength | ≥200 MPa |
| Hole Customization | CNC drilling, slotting, multi-layer stacking |
| Applications | EV battery modules, BMS, ESS, solar storage battery packs |
| Certifications | ISO 9001, RoHS, UL (on request) |
Electric Vehicles (EVs): Battery interconnections, BMS integration, cell-to-cell and module-to-module connections.
Renewable Energy Systems: Solar energy storage, wind power battery banks, off-grid and hybrid storage systems.
UPS & Industrial Backup Power: Fast, stable power transmission in high-current applications.
Data Centers & Telecom: Redundant battery power connections for uninterrupted operation.
Laboratory & Industrial Energy Modules: Custom modular busbars for battery testing and energy storage racks.
Select busbar size according to current and voltage requirements.
Use proper insulation or plating for corrosive environments.
Secure busbars to prevent mechanical stress and vibration.
Regularly inspect for oxidation, loose connections, or thermal issues.
Clean surfaces periodically to maintain low resistance and efficiency.
Custom Solutions: Full customization of Copper Busbar Connectors for Battery Pack to meet your exact requirements.
Premium Materials: T2 pure copper ensures high conductivity and low resistance.
Diverse Product Range: Solid, laminated, flexible, tin-plated, and insulated options.
OEM/ODM Capabilities: Prototyping, CNC machining, quality inspection, packaging, and global shipping.
Quality Assurance: Every busbar is tested for electrical and thermal performance before delivery.
Competitive Pricing & Reliability: Direct factory supply, cost-effective, and scalable for mass production.
Q1: Can you customize copper busbars for EV battery modules?
A1: Yes. We provide full customization including size, shape, hole positions, plating, insulation, and flexible or solid designs.
Q2: What type of copper do you use?
A2: T2 pure copper (≥99.9%) for high conductivity and low resistance.
Q3: Do you offer both solid and flexible battery busbars?
A3: Yes. We supply Solid Copper Busbar for Battery Pack, laminated, and Flexible Copper Busbar for Battery Pack options.
Q4: What are the benefits of tin or nickel plating?
A4: Tin improves oxidation resistance and weldability; nickel enhances protection in high-temperature or corrosive conditions.
Q5: Can I get a prototype before mass production?
A5: Yes. We offer low MOQ, fast sampling, and OEM support for prototypes.
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