Copper Battery Bus Bar For New Energy Vehicles
√ Simple to install and integrate into battery systems
√ Strong and robust, capable of withstanding mechanical stress.
√ Minimizes energy loss and heat generation.
√ Resistant to oxidation, ensuring longevity
√ Good thermal conductivity helps in effective heat dissipation.
As the core conductive element of the battery system, the copper battery bus bar adopts C11000/C10100 high-purity copper (copper content ≥99.9%), forming a low-resistance channel through precision processing. Its conductivity is in line with GB/T 5581.1 standard, hard state (TMY) conductivity ≥ 97% IACS, soft state (TMR) up to 100% IACS, effectively controlling the voltage drop at 0.01724-0.01777Ω-mm²/m, suitable for 30-2000A wide range of current-carrying needs.
| Item Type: | Copper battery bus bar |
|---|---|
| Material base: | Copper (C11000 or C10100) |
| Type: | Copper foil connector |
| Usage: | Car Battery Connector |
| Application: | Battery conducting,Electrical appliance |
| Length: | Customizable, typically up to 6 meters |
| Thickness of plating: | 3-5 μm |
| Insulation: | PE heat shrink tubes and PVC dipping |
| Processing Service: | Bending, Welding, Decoiling, Cutting, and punching |
| Rated Current | 30-40% (depending on the specific alloy and temper) |
| Hardness: | 40-80 HV (Vickers Hardness) |
| Rated Current: | 100-2000A |
| Feature: | Flexible |
Leading Copper Battery Bus Bar Manufacturer
Structure Design and Processing Technology Of Copper Battery Bus bar
1. Diversified structure
- Single busbar structure: simplify the installation process, suitable for standard battery modules.
- Multi-bus parallel structure: Redundant design by increasing the current-carrying cross-section (max. 100mm wide x 10mm thick), increasing current-carrying capacity by 40%.
2. Surface treatment technology
- Basic protection: 3-5μm tin plating (in accordance with EN 13601 CW004A)
- Special treatment: optional silver plating (contact resistance reduced by 15%) or nickel plating (salt spray resistance ≥ 500h)
- Insulation solution: double composite protection (PE heat-shrinkable tube + PVC dip molding), temperature resistance -40 ℃ ~ 125 ℃
Engineering application and performance Of Copper Battery Bus bar
1. Industry Adaptability
- New energy vehicles: meet ISO 26262 functional safety requirements, suitable for 400V high-voltage battery system.
- Energy storage system: UL1973 certified, support 6 meters long specification customization.
- Industrial: adopts diffusion welding process (page 1) and realizes 180° flexible bending.
2. Quality Assurance System
ISO 9001 certified digital production line equipped with:
- Three-dimensional laser cutting (precision ±0.1mm)
- Intelligent bending system (angle tolerance ≤0.5°)
- Online resistance testing (accuracy ±1%)
Technical Analysis of Copper Battery Bus bar
| Performance | Traditional Solution | New Solution | Enhancement |
|---|---|---|---|
| Conductivity Efficiency | 95% IACS | 97-100% IAC | ↑2-5% |
| Temperature Rise Control | ΔT≥30℃(200A) | ΔT≤15℃ | ↓50% |
| Corrosion Resistance | Salt Mist 96h | Salt Mist 500h | ↑420% |
| Processing Flexibility | Fixed specifications | Any cut within 6 meters | – |
Application Of Copper Battery Bus bar
1. New Energy Vehicle
Matching blade battery/cylindrical battery module, realizing ultra-low internal resistance of 0.15mΩ within the pack.
2. Smart Grid
Applied in power storage converter (PCS) to reduce system loss by ≥3%.
3. High Density Power Supply
AI data center power supply busbar supports 140A/mm² current density.
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