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Custom Solid Laminated Copper Flexible Busbar for New Energy Vehicle Battery Connection

The Custom Solid Laminated Copper Flexible Busbar for New Energy Vehicle Battery Connection is a critical component in the power distribution systems of new energy vehicles.
  • Nickel-49

  • ARIDA

  • 2024101605

  • >99.99% nickel

  • Local Service/Online Service

  • Nickel Plate

  • Stamping, Bending, Welding, Electroplating

  • Electricity

  • JIS, GB, BS, ASTM

  • 12 months

  • Electric Power Transmission

  • Standard Export Packing

  • Acoording to Client's Require to Provide Model

  • ARIDA

  • China

  • Solder The Nickel Sheet Onto Brass Sheet

  • High precision

  • Worldwide

  • Yes

Availability:
Quantity:
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Main Product


Custom Solid Laminated Copper Flexible Busbar for New Energy Vehicle Battery Connection5

The Custom Solid Laminated Copper Flexible Busbar is a high-performance electrical connector specifically engineered for new energy vehicle (NEV) battery connections. Made from multi-layer, high-purity copper, it combines excellent conductivity, mechanical flexibility, and long-term durability — ideal for modern electric vehicle (EV), hybrid (HEV), and plug-in hybrid (PHEV) battery systems.Its laminated structure allows easy shaping to fit complex or space-constrained battery pack layouts while minimizing energy loss and heat generation.

Product Description

Nickel Sheet for Battery Specification


Name
CS welding nickel tab nickel plated steel sheet
Material
nickel plated steel
dimension
Customized according to customers
Application
Battery Pack Connector. for lithium battery, prismatic battery
Craft
Solder the Nickel Sheet onto Brass Sheet.
Colour
Customizable
weight
Customized according to customers
Apply
Electric Power Transmission
Manufacturer
ARDIA
Place Of Origin
Guangdong,China
Processing Method
Stamping, bending, welding, electroplating
Key Components Features


Material Composition

  • Conductor: High-purity copper (Cu-ETP, ≥99.9%) – maximizes conductivity and minimizes resistivity.

  • Lamination: Multiple bonded copper layers for enhanced flexibility and mechanical strength.

  • Insulation: High-temperature resistant (PVC or silicone rubber, -40°C to 150°C).

Design Highlights

  • Flexible structure – multiple segments or continuous with flexible joints.

  • Customizable terminals – tabs and connection points tailored to your battery pack.

  • Optional nickel plating – prevents corrosion and ensures low-resistance connections.

Customization Options

  • Length, width, thickness (e.g., 10–200mm width, 0.5–10mm thickness, up to 10m length)

  • Terminal and tab positions

  • Insulation type (PVC, silicone rubber)

  • Color coding for easy identification

  • Anti-corrosion / anti-oxidation coatings


 Advantages


  • High conductivity → minimal resistance and heat loss

  • Durable construction → high tensile strength, long service life

  • Easy installation → bends into tight or irregular spaces

  • Reliable connections → reduces electrical failure risk

  • Fully customizable → reduces material waste and fitment issues

  • Safe operation → high-temp insulation & corrosion-resistant options


Applications


  • New Energy Vehicles (NEVs) – EVs, HEVs, PHEVs

  • Battery packs – energy storage systems, portable electronics

  • Power systems – renewable energy (solar/wind), industrial power distribution


Material Specifications


Property Specification
Conductor Cu-ETP, ≥99.9% purity
Lamination Multi-layer copper + high-strength heat-resistant adhesive
Insulation PVC or silicone rubber (-40°C to 150°C)
Plating (optional) Nickel-plated connection points
Width Custom (typically 10–200 mm)
Thickness Custom (typically 0.5–10 mm)
Length Custom (up to 10 m per segment)
Current rating Up to 3000A (depends on size/config)
Voltage rating Up to 1000V AC/DC
Flexibility Segmented or continuous flexible joints
Tensile strength High (suitable for mechanical stress)


Customzation Features
  • Length and Size: Available in various lengths, widths, and thicknesses to meet specific project needs.

  • Configuration: Customizable terminal and tab positions to ensure compatibility with different battery pack designs.

  • Insulation Types: Choice of insulation materials, such as PVC or silicone rubber, to suit various environmental conditions.

  • Color Coding: Optional color coding for easy identification and organization.

  • Special Coatings: Anti-corrosion and anti-oxidation treatments to enhance durability and performance.

FAQ

Q1: What is the maximum current rating for the Custom Solid Laminated Copper Flexible Busbar?

  • A1: The maximum current rating can vary depending on the size and configuration, but it can typically handle up to 3000A.

Q2: Can the busbar be installed in tight spaces?

  • A2: Yes, the flexible design allows the busbar to be easily bent and shaped to fit into tight spaces, simplifying installation.

Q3: What is the temperature range for the busbar's operation?

  • A3: The busbar operates effectively within a temperature range of -40°C to 150°C.

Q4: Is the busbar suitable for outdoor environments?

  • A4: Yes, the busbar is designed with corrosion-resistant nickel plating and high-temperature insulation, making it suitable for outdoor use.




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