Choosing the Right Copper State for Better Busbars

As the new energy sector continues to grow rapidly, copper busbars play a critical role in power transmission, directly impacting system efficiency and operational safety. Whether used for battery connections in EVs or power distribution in energy storage systems, copper busbars function like the “arteries” of the system, carrying current reliably and efficiently.

The condition of copper—such as annealed (soft), hard, or half-hard—greatly influences the busbar’s formability, electrical performance, production efficiency, cost, and lead time. Therefore, specifying the right material condition before production is essential to ensuring both quality and timely delivery.

Material Condition Clarity Enables Efficient Delivery

At RHI, clarifying the required copper condition is a critical step before production. If the customer does not specify it, our experienced engineering team will recommend the most suitable material condition based on the application—whether it involves dynamic flexible connections, high-voltage systems, or low-voltage efficient power distribution.

For applications requiring both good conductivity and formability, annealed or half-hard copper is often preferred. Annealed copper, processed through precision heat treatment, features lower hardness and excellent flexibility, making it ideal for complex forming and reducing the risk of cracking. Half-hard copper offers a balance of strength and ductility, suitable for scenarios requiring both shaping precision and mechanical performance.

Standard Inventory Covers Common Conditions

To ensure fast response and delivery, RHI maintains intelligent warehousing and a steady inventory of high-conductivity copper in various standard conditions, including annealed and half-hard. These materials support full-process production methods such as laser cutting, stamping, 3D bending, extrusion, and overmolding.

For example, annealed copper offers cleaner cuts and smoother edges in laser cutting, reducing post-processing needs. Half-hard copper maintains better dimensional accuracy in stamping, ideal for high-precision components.

Table of Copper Processing States: Classification and Codes

(Note: State codes and explanations comply with GB/T 2059-2020 Copper Alloy Strip and GB/T 1527-2020 Drawn Copper Tubes.)

Custom Copper Conditions for Specific Needs

For custom requirements beyond standard inventory, RHI offers tailored copper material conditioning using in-house annealing and tempering equipment. Based on specific technical needs, we control annealing temperatures and durations to achieve the desired material structure and performance.

However, customized conditions may involve additional setup and production steps. We provide transparent recommendations on minimum order quantities and lead times based on a thorough technical assessment. When appropriate, we may suggest adjusting material conditions to use standard inventory, helping reduce costs, shorten lead times, and minimize supply risks—without compromising quality.

Annealed Electrical Busbars for Flexible Installation

Annealed copper busbars are particularly suited for applications requiring flexibility and easy installation. In EV charging stations, for instance, frequent plugging and repositioning demand materials that can bend without breaking—annealed busbars meet this need effectively. In energy storage systems, these flexible busbars adapt to tight spaces and complex layouts, ensuring stable power transmission with efficient routing.

Smart Manufacturing Powers High-Quality Busbar Solutions

As a leading manufacturer in the new energy battery busbar sector, RHI leverages automated production lines, digital warehousing, and deep technical expertise to deliver full-process manufacturing services. We offer custom busbars in various material states and configurations, tailored to diverse application needs.

From material selection and cost control to process design and performance optimization, RHI provides expert solutions to meet evolving market demands—including enhanced heat resistance, custom surface treatments, and unique mechanical properties—ensuring reliable, high-performance copper busbar products.