EVパワーバッテリー用カスタムスポット溶接バッテリーバスバーコネクタ

√  効率的な電力配分を実現する高純度銅。

√  耐腐食性を高めるためのオプションです。

√  安全で安定したスポット溶接接続。

√  バッテリーセル端子と完全に一致します。

大手カスタムバッテリーバスバーコネクタメーカー

We use a composite process of laser spot welding and ultrasonic welding, which reduces the connection resistance to less than 0.15 mΩ. The lower buffer structure can increase the stress dispersion efficiency of the welding point by 40%, and the cycle life exceeds 5,000 times of charging and discharging tests. The technology has been applied to the 150 kWh solid-state battery pack of the Azalea ET7, realizing the temperature difference of the single cell to be controlled at ±1.5℃.
Cross-border integration of material science. The use of high-purity oxygen-free copper (purity ≥99.99%) with nanoscale nickel plating technology has increased the electrical conductivity to 102% IACS (International Annealed Copper Standard), while the salt spray resistance test has exceeded 2,000 hours. The copper-graphene composite material developed by AVIC Optoelectronics maintains conductivity stability under the working conditions of -40℃~150℃ and is successfully applied in the Tibetan Plateau Energy Storage Project.

What are the benefits Custom Battery Bus bar Connectors?

• High-purity copper or aluminum (nickel plating optional) for low resistance (<0.5mΩ) and high current-carrying capacity (up to 500A)
• Optimized elastic support and vibration damping structure to absorb mechanical stress and improve heat dissipation efficiency Process Accuracy
• Ultrasonic welding technology ensures consistent joints (tolerance <±0.1mm)
• Environmental Resilience Salt Spray Test (240 hours) and Wide Temperature Range Verification (-45℃ to 150℃)

なぜ当社を選ぶのでしょうか?

1. Specialized Technology
   • Deeply involved in the field of EV battery connection, providing integrated design of main busbar, connecting busbar and cooling unit.
   • Supporting parallel/series hybrid layout, suitable for cylindrical, square and other cell sizes.
2. 品質保証
   • Full-process testing: Strict control from raw material purity (copper ≥99.9%) to welding strength (tensile ≥50MPa).
   • Conforms to international standards such as UL 4128 and supports 10,000 times plug life verification.
3. Customized service
   • Design Flexibility: Provide floating connector (tolerance compensation ±1.5mm) and blind plug compatible program.
   • Fast response: 3D modeling + prototyping cycle time ≤ 7 days, support for small quantities (from 100 pieces) to millions of mass production.
4. Cost optimization
   • Increase material utilization by 30%, reduce processing loss by integrated stamping/bending process.

What is the application for battery Bus bar Connectors?

1. Electric Vehicle Power Battery Pack
   • Main circuit connection: connect the positive and negative terminals of the battery module to the high voltage box, support 800V platform design.
   • Sampling line integration: built-in FPC connector for synchronized voltage/temperature signal transmission.
2. Energy Storage System (ESS)
   • Containerized battery cluster interconnection, supporting 1500VDC system voltage.
3. 産業機器
   • Forklift/AGV power battery, shock and vibration resistant (IEC 61373 standard).

How is the customization process battery Bus bar Connectors?

1. Requirements analysis: Provide drawings or 3D models of battery pack stacks (STEP format recommended)
2. Simulation verification: conduct thermal-force coupling analysis through ANSYS to optimize current-carrying and structural strength.
3. Prototype testing: including:
   • Temperature rise test (ΔT≤40K@rated current)
   • Mechanical vibration (20Hz-2000Hz, 12 hours in each of the 3 axes).
4. Mass Production Delivery: Provide RoHS/REACH compliance report and process quality control documentation.

For complete technical documentation or sample requests, please contact our engineering team.