Aluminium Busbars with Heat-Shrink Insulation for EV Power Systems
Rigid aluminium busbars offer low resistivity, low heat generation, and a lightweight, compact structure, making aluminium busbars ideal for fixed, non-vibration connections in battery modules and control boxes. Their high current-carrying capacity supports efficient high-current transmission while reducing energy loss and cooling demand. Stable mechanical performance ensures reliable busbar connections under vibration and shock. Standardized designs simplify assembly, and strong environmental adaptability ensures electrical safety across the full lifecycle while minimizing maintenance costs.
Rigid aluminium busbars, made from 1060 aluminium, deliver low resistivity, lightweight construction, and high current-carrying capability, making them ideal for rigid internal connections in high-power EV battery modules and power control units. These aluminium busbars effectively reduce heat generation and energy loss, improving overall system efficiency. With reliable insulation, stable mechanical strength, and strong vibration resistance, these HV busbars ensure safe and stable electrical connections throughout the full lifecycle. Standardized designs support automated assembly, significantly increasing production efficiency while reducing total system cost.
| Parameter | Insulation Withstand Voltage | RoHS | Flammability Rating | Working Temperature | Insulation solution | Conductor Material |
| Values | 4000 V DC, 1 min | Qualified | UL94 V-0 | -50~125 °C | Heat-shrink insulation | 1060 aluminium |
Key Advantages
- Pure aluminium conductor with ≥62% IACS conductivity, low resistivity, and minimal heat generation
- Lightweight and cost-efficient with excellent current-carrying performance, reducing system energy loss and temperature rise
- Stable mechanical properties with strong vibration and shock resistance, preventing loosening and poor contact
- Standardized dimensions compatible with automated assembly, improving production efficiency
- Strong environmental durability, ensuring safe and reliable connections throughout the full lifecycle while lowering maintenance costs
Applications
Rigid aluminium busbars feature uniform cross-sections, dense material structure, and low impurity content, delivering low resistivity, minimal heat generation, a compact design, and weight reduction. They are well suited for rigid, fixed connections in vibration-free, space-defined applications such as control boxes and power battery systems, and are widely used in new energy vehicle platforms.
