Copper-to-Aluminum Busbars for New Energy Systems

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:

Copper-Aluminium Busbars with Friction Welding

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.