Key Manufacturing Processes
1. Copper Laminated Busbar Forming
The flexible conductor is formed by laminated welding of multiple T2 copper foils, ensuring a uniform cross-section without delamination while providing both high current-carrying capacity and excellent flexibility.
2. Cu-Al Dissimilar Metal Joining
The aluminum terminal is ultrasonically welded to the copper laminated busbar, creating a solid-state metallurgical bond through high-frequency vibration. This process ensures low contact resistance, no false welding, and long-term connection stability, meeting the reliability and mass-production requirements of the new energy industry.
3. Insulation Protection Process
The main conductor is fully insulated with flame-retardant heat-shrink tubing and protected by an abrasion-resistant braided sleeve. Customized insulating covers are additionally applied to the aluminum terminals to provide enhanced electrical isolation and prevent creepage and short-circuit risks.
4. Surface Finishing Process
Tin or nickel plating is available to improve oxidation and corrosion resistance. The braided sleeving further enhances abrasion resistance and bending durability for demanding operating environments.
Product Advantages
1. Cu-Al Transition Design
Optimized for dissimilar metal connections between aluminum battery terminals and copper busbars, reducing galvanic corrosion risk.
2. Low Resistance & Stable Current Carrying
Ultrasonic welding ensures oxidation-free bonding with extremely low contact resistance, while the high-conductivity copper laminated busbar delivers low temperature rise and reliable high-current performance.
3. Dual Insulation Protection
Heat-shrink tubing, insulating covers, and braided sleeving provide enhanced insulation and mechanical protection against short circuits, creepage, and abrasion.
4. Flexible & Vibration Resistant
The multi-layer copper laminated structure offers excellent flexibility and fatigue resistance, effectively absorbing vibration and installation stress in demanding ESS and EV battery applications.
5. Highly Customizable
Customizable in cross-section, length, terminal holes, bending angles, and plating options for various battery modules, ESS cabinets, and electrical systems.
6. RoHS Compliant & Quality Assured
Manufactured with RoHS-compliant materials under the IATF 16949 quality management system for reliable quality and full traceability.
Applications
Cu-Al flexible busbars for EV battery cells, battery modules, and PACK systems
Battery cluster and cabinet busbar connections in residential and commercial ESS
Flexible Cu-Al busbar transitions in power distribution and switchgear systems
High-current flexible connectors for PV inverters and UPS systems
Electrical connections requiring vibration resistance or displacement compensation in industrial automation and motor control systems
