Custom T2 copper flat busbar for EV battery packs, energy storage systems, electrical panels and switchgear. Supports efficient power distribution, space-saving installation, optional plating and OEM/ODM manufacturing.
√ Flat profile saves space and allows for easy installation.
√ Minimal electrical resistance for optimal energy efficiency.
√ Robust construction provides long-term reliability.
√ Suitable for indoor and outdoor use without degradation.
√ Can be tailored in width, thickness, and length to fit specific needs.
| Item Type: | flat copper busbar |
|---|---|
| Material base: | pure T2 copper |
| Shape: | Rectangular |
| Width: | Customizable, typically ranging from 10 mm to 100 mm |
| Thickness: | Customizable, typically ranging from 1 mm to 10 mm |
| Length: | Customizable, depending on application requirements |
| Conductivity: | High electrical conductivity for efficient power transmission |
| Resistance: | Low electrical resistance to minimize energy loss |
| Surface Finish: | Bare copper or optional plating (e.g., tin, silver) for enhanced corrosion resistance |
| Operating Temperature: | Suitable for temperatures ranging from -40°C to +125°C |
| Applications: | Power distribution systems Electrical panels Switchgear Automotive Renewable energy systems |
As a manufacturer of flat copper busbars, we specialize in delivering high-quality products known for their excellence in conductivity, durability, and versatility. Our busbars, crafted from copper materials, are meticulously engineered to meet the highest industry standards.
1. Material pretreatment
6 sets of precision straightening rollers are used to straighten the copper strips, synchronized with ultrasonic cleaning (cleaning cotton is automatically replaced every 80m)
2. Cold extrusion molding
Through the multi-stage cold extrusion mold (die hole precision ± 0.01mm) will be round copper wire calendering to the target cross-section, molding process control temperature ≤ 50 ° C.
3. Short-circuit annealing
DC annealing process (1-35A/7-11V), with 25-37 ℃ dynamic circulation of pure water cooling system, eliminating processing stresses
4. Surface treatment
Optional 3M insulating material coating or micron-level plating (tin / silver), coating curing using three-stage temperature control (80 ℃ → 120 ℃ → 160 ℃)
5. Intelligent detection
Integrated online spectral analysis (component detection) and X-ray flaw detection (defect detection rate ≥ 99.9%)
1. Efficient conductivity
Laminated structure design, compared with the solid busbar to enhance 30% of the current-carrying capacity, the skin effect is reduced by 40
2. Space optimization
Flat structure to achieve 90% space utilization, suitable for 600mm ultra-narrow cabinet layout.
3. Thermal management breakthrough
Honeycomb hollow design reduces weight by 40%, and with forced air cooling system, temperature rise is controlled within 35K.
4. Environmental Tolerance
-40 ℃ ultra-low temperature coating technology to ensure the stability of conductivity in cold environments, 125 ℃ high temperature insulation layer to maintain ≥ 100MΩ impedance
5. Intelligent integration
Support PCB pre-drilling (± 0.01mm positioning accuracy), automated assembly efficiency by 60%.
1. Material innovation: copper-aluminum composite busbar research and development has achieved a weight reduction of 35%, 20% lower cost
2. Manufacturing upgrades: fully automated production line to achieve 600mm × 15mm large cross-section of a single molding, 300% increase in production capacity
3. Functional integration: intelligent busbar embedded with fiber optic sensors can realize multi-parameter monitoring of temperature, current and deformation.
4. Green manufacturing: electrolytic polishing wastewater recycling rate of 95%, unit energy consumption reduced to 60% of the traditional process.
At present, we have launched Flat-PLS series products supporting 5500A current, supporting intelligent connection system can increase the installation efficiency by 80%. Customiers are advised to focus on the matching of current-carrying capacity and temperature rise when selecting a model, and prioritize manufacturers that have passed the IEC 61439-2 certification.
| Item Type | Flat Copper Busbar |
|---|---|
| Material Base | High-Purity T2 Copper |
| Structure | Rectangular Flat Strip |
| Surface Treatment | Bare Copper, Tin or Silver Plating |
| Electrical Function | Power Distribution Connection |
| Customization | Size, Holes and Surface Finish |
