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Copper-to-Aluminum Busbars, Custom Busbars for New Energy

Copper-to-Aluminum Busbars, Custom Busbars for New Energy

The copper-to-aluminum busbar features an aluminum conductor with copper terminals diffusion-bonded at both ends in a lap-joint configuration. This cost-effective alternative to solid copper busbars significantly reduces weight and cost while maintaining high conductivity. Optional tin or nickel plating and design optimizations further enhance performance for specific new energy applications.

  • Plating： Tin plating, nickle plating, sliver plating
  • MOQ： 100 (Negotiable)
  • Size： Customized
  • Conductor Material： T2 copper/1060 aluminum
  • Insulation： PVC/EVA/PE
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Key Advantages:

  1. Cost Savings: Aluminum, as the main conductor, is much cheaper than copper, significantly reducing material costs, especially in large-scale applications.

  2. Weight Reduction: Aluminum's density is one-third of copper's, making copper-aluminum busbars lighter, improving transport and installation efficiency—ideal for electric vehicles and renewable energy systems.

  3. Superior Conductivity: Butt welding ensures reliable copper-aluminum connections, combining copper's high conductivity with aluminum's cost-efficiency.

  4. Improved Heat Dissipation: Aluminum's better thermal conductivity allows for faster heat dissipation, increasing equipment stability and lifespan.

  5. Environmentally Friendly: Aluminum has a lower environmental impact than copper, reducing carbon emissions and supporting sustainability goals.


Product Show:

Copper-to-Aluminium Busbar


Specifications:

Plating Options:Nickel Plating 
Silver Plating
Tin Plating    
Insulated Finishes:

PE, PVC, PA12, PET and Epoxy Powder Coating

  • PE: Withstand Voltage 2700V AC, Working Temperature -40℃ to 125℃,

    Flame Retardant UL224 VW-1. Used for rigid & flexible busbar, but it can

    not be used for special-shaped products.

  • PVC (Dipping): Withstand Voltage 3500V AC, Working Temperature -40℃

    to 125℃, Flame Retardant UL94V-0. Used for rigid & flexible busbar, and

    can be used for special-shaped products.

  • Epoxy Powder Coating: Withstand Voltage 5000V AC, Working Temperature

    -40℃ to 150℃, Flame Retardant UL94V-0. Used for rigid busbar.

  • PVC (Extruded): Withstand Voltage 3500V AC, Working Temperature -40℃

    to 125℃, Flame Retardant UL94V-0. Used for flexible busbar.

  • PA12 (Extruded): Withstand Voltage 5000V AC, Working Temperature -40℃

    to 150℃, Flame Retardant UL94V-0. Used for rigid busbar.

  • PET: Withstand Voltage 5000V AC, Working Temperature -40℃

    to 125℃, Flame Retardant UL94V-0. Used for rigid busbar.

re Finish 
Edge:Full Round Edges 
Rounded Corners 
Square Corners    
Voltage Type: AC 
DC
Production Capabilities:Bending 
Brazing 
Drilling 
Forming 
Milling 
Plating 
Punching 
Sawing 

Tapping    

Riveting

Industries Served:Aircraft 
Automotive 
Electrical 
Switch Gear    
Engineering Capabilities:Design Assistance 
Design Verification  
File Formats Accepted: 

JPG

PDF

DWG

DXF


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RHI – Copper and Aluminum Busbar Experts

RHI – Copper and Aluminum Busbar Experts



label: Cu-Al Busbar Custom Busbar

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