Insulated Flexible Copper Busbar with Plated Surface & EVA Insulation, 125A–1600A
In battery modules and packs, flexible copper busbars are widely used for electrical connection between cells, modules, and power terminals due to their excellent current-carrying capability, flexibility, and reliability. Compared with traditional rigid copper busbars or cables, laminated flexible busbars are designed to provide reliable flexible connections between battery components, reducing mechanical stress caused by vibration, thermal expansion, and assembly deviation while improving installation flexibility in EV and energy storage systems.
Features
Flexible busbar is formed with multiple layers of thin electrolytic copper, available in plain or tin plated.
Flexibar connections are made by punching directly through the laminates. There are no lugs to purchase, helping to eliminate faulty connection problems and making installation simpler and faster.
Insulation is provided by high-resistance, self-extinguishing EVA/PE heat-shrink tubing.
Easily bent,folded and twisted, flexible busbar improves assembly flexibility, shortening connections and decreasing footprint.
RoHS compliant and UL94 V-0 standard.
Specifications
1. Copper layer thickness from 0.5 to 1mm.
2. High flexibility & conductivity ETP grade copper (Cu) with a minimum copper content of 99.90%, can be tin plated on request.
3. Working temperature: -40 up to 125℃.
4. Voltage: 3500V AC.
5. Flame retardant: UL94 V-0.
6. High elongation value and mechanical resistance.
7. High current withstanding capacity and high conductivity.
8. Cross-sectional area: 24mm² to 1200mm².
9. Holes are punched through the laminated foils and can be round or oblong on request.
IMPORTANT!RHI can also drill or punch holes, form(bend and shape) and custom-cut flexible busbars to any size you need.
For custom flexible busbar options, please email us [email protected] or call us at 0086-15868025551.
Why Are Flexible Copper Busbars Used in Battery Modules and Packs?
In EV battery modules and packs, electrical connections must handle high current, limited installation space, vibration, and long-term thermal cycling. Traditional rigid copper busbars may create mechanical stress on battery terminals, while cables often have limitations in current capacity, layout flexibility, and assembly efficiency.
Flexible copper busbars provide a reliable solution with low electrical resistance, high current capacity, and excellent flexibility. The multi-layer copper foil structure helps reduce voltage drop and heat generation during high-power operation, while the flexible design absorbs vibration, thermal expansion, and assembly tolerances, reducing stress on battery cells and connection points.
With customizable shapes, terminal designs, and insulation options, laminated flexible copper busbars enable compact and reliable connections between battery cells, modules, and power distribution components, making them widely used in EV batteries and energy storage systems.
Why Choose RHI BUSBAR?
1. Advanced Technology: We have industry-leading processes and technologies like automatic robot dipping, automatic robot welding, automatic copper forming and 20 years’ experience of busbar insulated dipping technology. With automation equipment and R&D team, we continuously improve our production efficiency and product quality reliability.
2. Efficient Supply Chain: From raw materials to finished products, all processes include mould and fixture are finished in our plant. Only the plating is finished by our supplier near our factory.
3. Superior Service: Give response in 8 hours, arrive at customer’s site to solve problem in 24 hours ( Site outside China may need to be extended).
4. Quick Response: With efficient supply chain and perfect production process, we can provide small batch products in a short time to support early development of customer’s project.
5.Quality Commitment: We are committed to the highest quality standards. Material is tested before production to guarantee it is ETP grade copper. All goods are inspected before delivery. We have certificates of ROHS, REACH, UL94V-0, ISO14000 and IATF16949.
6. Timely Delivery: Experienced workforce, large production capacity and sound supply chain guarantee timely delivery time for customer.
7. Competitive Price: With efficient supply chain and production environment in China, we have advantage of low cost.
