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Aluminium Busbars for Lightweight, Cost-Effective Battery Interconnection
Designed for EV battery modules, this aluminium busbar with PVC insulation enables lightweight, cost-effective power distribution. High-precision forming ensures accurate dimensions and seamless pack assembly. Versus copper, it lowers weight and cost without compromising current-carrying reliability. The PVC layer delivers electrical isolation and wear resistance, reducing short-circuit hazards and improving system safety.
PVC-Coated Aluminium Busbar for EV Battery Modules
This PVC-coated aluminium busbar supports series and parallel connections within EV battery modules, offering a lightweight, cost-effective power distribution solution for highly integrated battery systems.
Key Advantages
- Lightweight and Low-Cost Design: Using aluminium instead of copper significantly cuts both weight and material expenses, helping reduce overall vehicle mass and enhance system efficiency.
- Precision Custom Fabrication: Bending, punching, and pre-forming are performed to customer specifications, ensuring accurate fitment to cell terminals, module end plates, and pack structures while streamlining assembly.
- Robust Insulation Protection: The uniform PVC coating delivers strong electrical insulation and resistance to abrasion, lowering short-circuit risks from vibration, friction, or mechanical wear, and improving safety and reliability.
| Parameter | Withstand Voltage | RoHS | Flammability Rating | Working Temperature | Insulation Thickness | Conductor Material |
| Values | DC 4000 V, 1 min | Qualified | UL94 V-0 | -40~125°C | 0.8-2 mm | 1060 aluminium |
Manufacturing Process
- Precision Forming: Controlled bending compensation ensures dimensional stability and consistent fit.
- Accurate Punching: Tight tolerances on mounting holes and connection points. Supports both bolted and welded termination methods.
- Automated PVC Coating: Precisely managed heating, coating, curing, and cooling. Provides high dielectric strength, low resistance, and a smooth, defect-free insulation surface.
RHI Strengths
RHI Electric is a custom manufacturer of copper and aluminium busbars based in Yueqing, Zhejiang, China. With over 40,000 m² of modern manufacturing facilities, a production workforce of more than 1,000, and over 10 years of industry experience, we are IATF 16949 certified, and our products meet RoHS requirements. Equipped with an in-house laboratory and tooling development center, we provide customized copper and aluminium busbar solutions for customers in the new energy vehicle and energy storage industries.
