Custom insulated copper battery busbar featuring a rigid formed conductor, exposed electrical contact zones and a welded multi-stud contact plate. Designed for EV battery packs, energy storage assemblies and OEM electrical connection projects.
This custom battery busbar uses a rigid formed copper or copper-alloy conductor with orange insulation covering most of the conductive body while leaving selected electrical contact areas exposed. The assembly incorporates punched connection holes, bent sections and a welded metallic contact plate with multiple studs, supporting mechanical fastening and electrical interconnection within a compact assembly. Its construction is consistent with insulated battery-busbar designs used for customized power connections.
The component is suitable for customized EV battery packs, energy storage systems and related power-electronics assemblies where an insulated rigid conductor must connect multiple mounting or terminal interfaces. For OEM sourcing, the formed geometry, hole pattern, exposed contact areas, insulation coverage and welded connection plate can be manufactured according to customer drawings and assembly requirements
Material & Insulation: The main body is made of high-conductivity copper. The majority of the busbar is coated with a bright orange insulating layer (likely a dielectric coating or heat-shrink tubing). This insulation is critical for preventing short circuits and ensuring electrical safety in high-voltage environments.
Welded Connection Plate: A distinct, wider metal plate (appearing to be stainless steel or nickel-plated) is welded to the lower section of the copper busbar. This plate features multiple threaded studs (or weld pins), which are designed for laser welding or bolted connection directly to the battery cell terminals.
Mounting & Contact Points: The upper and side sections of the busbar feature exposed copper areas with circular holes. These are intended for bolting to other conductive components or busbars within the electrical system.
This type of busbar is widely used in electric vehicle (EV) battery packs, stationary energy storage systems, and power electronics, where reliable and insulated high-current connections are required.
| Jenis Produk | Insulated Battery Busbar |
|---|---|
| Bahan | Copper C11000, Cu-EPT |
| Struktur | Rigid Formed Busbar with Welded Contact Plate |
| Penebat | Orange Insulating Coating over Main Conductive Body |
| Connection | Exposed Contact Areas with Bolt Holes and Studs |
| Proses Pembuatan | Forming, Punching, Insulation and Welding |
| Configuration | Bent Multi-Level Conductor with Integrated Contact Plate |
| Permohonan | EV Battery Packs, Energy Storage and Power Electronics |
