Flexible Copper Busbars for EV Battery Applications

Flexible copper busbars use multiple layers of electrolytic copper foil as the conductive base material. Both ends are securely joined through diffusion welding, followed by precision punching, edge rounding, and nickel strip attachment.

Heat-shrink insulation provides reliable electrical protection. Combining excellent electrical conductivity, flexibility, and insulation performance, these busbars are an ideal solution for flexible electrical interconnections in electric vehicle battery modules.

Features

• High Conductivity – Multi-layer electrolytic copper foil for efficient current transmission.

• Diffusion Welding – Strong, reliable welded connections.

• Precision Processing – Accurate punching and smooth, rounded edges.

• Heat-Shrink Insulation – Reliable electrical insulation and protection.

• Nickel Strip Attachment – Nickel strip application enhances corrosion resistance and improves end-terminal weldability.

Why Are Flexible Copper Busbars Essential for Battery Connections?

Flexible copper busbars accommodate vibration and thermal expansion, reducing stress on battery cell terminals and welded joints. Their excellent flexibility enables easier routing in compact battery packs, while high-conductivity T2 copper ensures low resistance and high current-carrying capacity. Combined with flame-retardant, moisture-resistant heat-shrink insulation, they provide reliable electrical protection, improved connection durability, and greater space efficiency compared with rigid busbars.

Applications

RHI flexible copper busbars use high-purity laminated copper foil to provide high conductivity and low contact resistance, helping reduce I²R losses and heat generation under high-current conditions. They are designed for flexible interconnections in EV high-voltage circuits, energy storage battery packs, and power conversion systems.

• EV Battery Pack Connections: Connects battery cells and modules, accommodating vibration and thermal expansion.

• Battery Module Interconnections: Provides flexible electrical connections between battery modules and terminals.

• High-Voltage Junction Boxes: Connects high-current components within EV power distribution systems.

• Energy Storage Systems (ESS): Enables flexible high-current connections across battery modules, series-parallel battery cluster configurations, battery racks, and power conversion systems.

Why Industry Leaders Choose RHI

• Engineering Support from Design to Production: RHI provides engineering support throughout product development, from design review and process evaluation to tooling development and production preparation. We work with customers to optimize product structures and manufacturing processes based on specific application requirements.

• Integrated Manufacturing Capabilities: With three production bases, automated production lines, and in-house capabilities across key manufacturing processes, RHI supports flexible production from prototype development to volume manufacturing. Digitalized workshop management helps improve production coordination, process control, and manufacturing traceability.

• Established Quality Management & Testing Systems: RHI implements quality control throughout the manufacturing process, covering incoming material inspection, in-process quality checks, and final product testing. Our in-house testing facilities support product verification and help ensure consistent quality and compliance with customer requirements.

• In-House Production & Delivery Control: With key manufacturing processes managed in-house, RHI maintains direct control over production planning, process execution, and quality inspection. This integrated approach supports production coordination, delivery management, and flexible responses to customer requirements.

RHI bends, punches, welds, rivets, and dips in-house, and uses automatic robots to raise capacity. A project engineering team helps customers hold cost and keep the connection stable.