Solid Copper Busbar For Electric Vehicles
Products Description
The high-voltage connection environment of electric vehicles is complex, requiring Solid copper Busbar for Electric Vehicles to maintain extremely high stability under high current surges, high temperature rises, high vibrations, and high-density wiring.
Our pure copper busbars use T2/TU1 electrolytic copper, which features extremely low resistance, high ductility, and excellent heat treatment properties, giving them excellent current-carrying capacity and thermal cycling life in high-voltage platforms.
Their main functions include:
High-voltage power circuit connection (power battery terminals → PDU → three-electric system)
Internal current transmission and distribution (inverter/OBC/DC-DC internal copper busbars)
High current carrying capacity (main current path design)
Replacing traditional wiring harnesses with complex wiring structures (improving vehicle lightweighting and stability)
Achieving a safe, low-loss, and highly reliable current transmission path
Core Functions
High Voltage, High Current Transmission
Adapts to 300V-800V high voltage platforms, stably carries 200A-800A rated current, supports 1000A+ short-term fast charging current surges, reduces power loss by 20% compared to traditional distribution busbar, improving fast charging efficiency and range performance;
Safety Isolation and Protection
Double insulation and optimised creepage distance prevent high voltage leakage and short circuits, ensuring the safety of passengers and the vehicle's electrical system.
Vibration-Resistant and Stable Operation
Maintains reliable connection even under wide-frequency vibration environments in vehicles, with no sudden changes in contact resistance or risk of loosening, ensuring continuous power output.
Efficient and Balanced Heat Dissipation
Optimised heat dissipation structure combined with a high thermal conductivity substrate quickly dissipates concentrated heat, avoiding insulation ageing or conductivity degradation caused by localised overheating.
Core Value Created for Customers
Enhanced Vehicle Range and Performance
Extremely low DC resistance and AC loss reduce energy waste during transmission, effectively increasing usable battery energy. Excellent thermal management supports more sustained high power output, improving vehicle performance.
01
Enhanced System Safety and Reliability
Automotive-grade design, materials, and verification standards fundamentally eliminate major safety hazards caused by component failures. Long-life design ensures reliable electrical connections throughout the vehicle's lifecycle, reducing after-sales risks and costs.
02
Achieved Higher Power Density and Cost Optimisation
Compact and efficient design saves valuable space and weight for the battery pack and electric drive system, supporting the integration of higher energy density batteries and more efficient electric drive systems. Platform-based design and efficient manufacturing processes help customers optimise total system cost while improving performance.
03
Accelerated Product Development and Time to Market
Solid copper bus bar providing end-to-end support from design simulation and rapid prototype production to mass production delivery, along with extensive platform-based design experience, significantly shortens customers' engineering development and verification cycles.
04
Detailed Showcase: Professional Craftsmanship in the Silence
| Rounded Edge Treatment | All positive and negative bus bar edges and hole edges are deburred and rounded to prevent damage to the insulation layer or wiring harness during assembly and to avoid electric field concentration. |
| Laser Marking Traceability | Laser engraving is used in non-critical areas to permanently mark material numbers, batch numbers, and production dates, enabling full lifecycle quality traceability. |
| Cleanroom Packaging | Anti-static and dustproof vacuum packaging ensures that products arrive at the final assembly line with clean, uncontaminated surfaces, meeting the stringent assembly requirements of automotive electronics. |
| Customized Marking | Functional markings and positive/negative symbols can be silkscreened or laser-engraved on the copper battery bus bar surface according to customer requirements, improving the accuracy and efficiency of on-site assembly. |
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