Aluminium Busbars for 800V HV Battery Interconnection
Manufactured from 1060 aluminium, this battery busbar features precision bending, PVC dip insulation, selective insulation stripping, and precision punching for seamless integration into standardized battery pack assemblies. Its lightweight, cost-effective design provides excellent electrical conductivity and thermal performance for EV battery module interconnection, helping reduce vehicle weight while improving the efficiency and reliability of electric vehicles.
Product Description
PVC dip insulation for aluminium busbars is achieved by preheating the aluminium substrate before immersion in liquid PVC plastisol. After plasticization and curing, a uniform, dense insulation layer is formed to provide reliable high-voltage electrical insulation for EV battery packs.
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| Parameter | Withstand Voltage | RoHS | Insulation Material | Temperature Resistance | Insulation Thickness | Conductor Material |
| Values | DC 4000 V, 1 min | Qualified | PVC Dip Coating | -40~125°C | 0.8-2mm | 1060 aluminium |
Application
As the primary current-carrying conductor within the battery pack, the aluminium busbar enables high-current distribution between battery cells, modules, the Battery Disconnect Unit (BDU), and high-voltage connectors. Its low-resistance design minimizes power loss while ensuring efficient power transmission.
With the widespread adoption of 800V fast-charging platforms, aluminium busbars have evolved beyond simple conductors to become critical power distribution components in EV battery systems. Their dielectric strength, current-carrying capacity, thermal performance, and electrical stability directly influence fast-charging capability, energy efficiency, and high-voltage safety.
