What is the cost optimizing solutions of copper-to-aluminum conversion?

12/08 Copper-to-aluminum 30

Since the birth of automotives, cost optimizing solutions has been one of the most effective measures to reduce fuel consumption and carbon emissions. In recent years, the penetration rate of new energy vehicles has been increasing. Compared to traditional gasoline vehicles, electric vehicles eliminate the engine and some additional systems, adding the "three electric systems (battery, motor, and electronic control)," making them heavier and bad to vehicle performance. Therefore, cost optimizing solutions is more urgently needed for new energy vehicles.

Research has shown that for every 10% reduction in the overall weight of an electric vehicle, the range can increase by about 5%-6%. Consequently, cost optimizing solutions technology has become one of the crucial directions for the development of new energy vehicles worldwide.

Here are some specific measures for cost optimizing solutions :

Material Selection: Use cost optimizing solutions, high-strength materials such as carbon fiber composites, aluminum alloys, magnesium alloys, etc., to replace traditional heavier materials like steel.

Structural Optimization: Improve vehicle structural design by reducing redundant components and materials, achieving a more compact and efficient structure to lower the overall vehicle weight.

Component Cost Optimizing Solutions: Optimize the design of various vehicle components, using lightweight parts such as lightweight seats and suspension systems.

Battery Technology Improvement: In electric vehicles, the battery is a crucial component. Improving battery technology through copper to aluminum upgrade busbars enhances energy density while reducing battery weight, significantly improving the vehicle's range.

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In new energy vehicles, copper busbars, as a key conductive material, play an important role in current conduction within the battery system, electric drive system, and the entire electrical system. While, cost optimizing solutions the conductive materials, such as aluminum busbars, aluminum alloy or other high-strength lightweight metals, has become an ideal choice for effectively reducing overall vehicle weight and improving energy efficiency.

In the high-voltage series and parallel connections of battery packs, although copper connecting strips have good high-voltage connection performance, the trend is shifting towards using pure aluminum (1060/6101) instead of copper due to the relatively high density of copper (8.9g/mm3). While meeting the overcurrent capacity requirements, the use of aluminum reduces weight by more than 30% and comes at a lower cost.

The safety current carrying capacity of copper is generally 5-8A/mm2, while aluminum is 3-5A/mm2. With aluminum's density being approximately one-third of copper's, and under the same overcurrent requirements, weight can be reduced by more than 30%. Copper to aluminum migration busbars provide a more economical and efficient solution for the sustainable development of new energy vehicles.

As a leader in the Chinese busbar industry, our company has extensive experience in copper-aluminum welding, copper aluminum transition busbars, hybrid welding, aluminum-aluminum welding, and up to seven different processes. We can provide customers with cost-effective solutions without compromising performance.


The cost optimizing solutions of new energy vehicles is an inevitable choice in embracing the era of electrification in automotives. As new technologies continue to emerge and the new energy vehicle market matures, cost optimizing solutions will continue to play a crucial role, providing reliable support for the sustainable development of the automotive industry and user experience. Through continuous efforts, cost optimizing solutions of new energy vehicles will open up broader development prospects, contributing greater efforts to environmentally friendly travel and energy conservation.

TAG:  cost optimizing solutions copper aluminum RHI