Copper-to-Aluminum Busbars for New Energy Systems

Copper-to-aluminum busbar combines copper’s conductivity and stability with aluminum’s weight and cost advantages. This custom busbar' structure offers low contact resistance and high energy efficiency. It is widely used in automation, metallurgy, power systems, and is especially vital in EV battery packs and high/low voltage equipment—delivering a reliable and cost-effective solution for modern energy applications.

Product Description:

The development of copper-aluminum composite busbars aims to address the inherent conductivity weaknesses of aluminum busbars. Aluminum is a softer material with faster creep rates, leading to loosening over time. Additionally, prolonged use increases surface contact resistance, resulting in electrical degradation and potential loss of conductivity. 

Copper-aluminum busbars ensure safety, reliability, and longevity while significantly reducing costs. Testing shows a fundamental difference in electrical performance compared to aluminum busbars, offering much longer service life and higher reliability, with safety on par with copper busbars. Furthermore, copper-aluminum busbars are lighter, easier to install, and experience less bending stress from their own weight, making them a highly cost-effective solution.


Cu-Al Bimetallic Bus Bar Advantages:

  • Produced by innovative patent technology——Solid-Liquid machining processing technique to bond copper and aluminum permanently and firmly;

  • With higher electric conductivity: Can reach more than 98% of the same volume conductivity of pure copper;

  • Lighter than pure copper: About 1/3 weight of the same volume of pure copper;
  • Lower cost than pure copper;
  • 90 degree bend do not wrinkle, stamping no cracking, easy processing;
  • Meet all thickness between 0.20mm to 15mm in ratio of 20Cu:80Al by thickness for Cu-Al Bimetal;
  • Unlimited for length and area.


Product Show:

RHI-Offering Copper & Aluminum Busbar Connection Solutions


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


Why Choose RHI BUSBAR?

  • Advanced Manufacturing
    With 20+ years of experience in insulated dipping and automated processes—including robotic dipping, welding, and copper forming—RHI leverages cutting-edge technology to ensure high efficiency, precision, and product consistency.

  • Integrated Production
    From raw material processing to mold and fixture fabrication, all critical steps are completed in-house—except for plating, which is handled by a certified nearby partner—ensuring full process control and quality traceability.

  • Responsive Support
    We respond within 8 hours and offer on-site technical support within 24 hours in China (lead time may vary for overseas support), ensuring fast resolution for customer needs.

  • Agile Prototyping
    Thanks to a streamlined supply chain and flexible production setup, we can deliver small batches quickly to accelerate early-stage development and validation.

  • Quality Assurance
    We use certified ETP-grade copper, conduct 100% inspection before shipment, and comply with ROHS, REACH, UL94 V-0, ISO14001, and IATF16949 standards to meet global quality and safety requirements.

  • On-Time Delivery
    With a skilled workforce, robust capacity, and reliable logistics, we consistently meet tight delivery schedules—even for high-volume or customized orders.

  • Cost Advantage
    Our vertically integrated operations and manufacturing base in China allow us to offer competitive pricing without compromising quality or service.


Enterprise Showcase

RHI-Offering Copper & Aluminum Busbar Connection Solutions

RHI-Offering Copper & Aluminum Busbar Connection Solutions

Related Content