Aluminium Busbars with PVC Insulation for Battery Modules
Aluminium Busbar for EV Battery Modules features a lightweight aluminium conductor and durable PVC insulation coating for efficient and cost-effective power distribution. Precision-engineered bending and punching ensure excellent dimensional accuracy and easy integration into battery pack systems. Compared with copper alternatives, the aluminium bus bar helps reduce weight and material costs while maintaining reliable current-carrying performance. The PVC-coated insulation layer provides effective electrical isolation and abrasion resistance, minimizing short-circuit risks and improving battery system safety and reliability.
PVC-Coated Aluminium Busbar for EV Battery Modules
Designed for series and parallel connections in EV battery modules, this PVC-coated aluminum busbar provides a lightweight and cost-effective power distribution solution for highly integrated battery systems.
Key Benefits
Lightweight & Cost-Efficient
- Aluminum conductor reduces weight and material costs compared with traditional copper busbars.
- Supports vehicle lightweighting and improved system efficiency.
Precision Custom Manufacturing
- Precision bending, punching, and pre-forming based on customer design requirements.
- Ensures accurate alignment with cell terminals, module end plates, and battery pack structures.
- Simplifies installation and improves assembly efficiency.
Reliable Insulation Protection
- Uniform PVC coating provides excellent electrical insulation and abrasion resistance.
- Reduces the risk of short circuits caused by vibration, friction, or mechanical wear.
- Enhances battery system safety and operational reliability.
| Parameter | Withstand Voltage | RoHS | Flammability Rating | Working Temperature | Wall Thickness | Conductor Material |
| Values | DC 4000 V, 1 min | Qualified | UL94 V-0 | -40~125°C | 0.8-2 mm | 1060 Aluminium |
Technical Features
Optimized for Advanced Battery Architectures
- Suitable for CTP (Cell-to-Pack) and CTC (Cell-to-Chassis) applications.
- Supports fast positioning and efficient automated assembly.
Environmental Durability
- PVC insulation offers good resistance to moisture, chemicals, and vibration.
- Designed for demanding EV operating environments.
Manufacturing Process
Precision Forming
- Controlled bending compensation ensures dimensional accuracy and consistent fitment.
Accurate Punching
- Tight tolerance control for mounting holes and connection points.
- Compatible with bolted and welded connection methods.
Automated PVC Coating
- Precisely controlled heating, coating, curing, and cooling processes.
- Delivers high dielectric strength, low resistance, and a smooth, defect-free insulated surface.
Application
Designed for series/parallel connections within EV battery modules, this aluminum busbar achieves lightweighting, cost efficiency, and precision installation for highly integrated battery systems. Its aluminum‑replaces‑copper design, with cross‑section optimized to actual module current ratings, cuts material cost and weight, supporting vehicle mass reduction and increased range.
