Copper Busbar Heat-Shrink Insulation for EV and Energy Storage Battery Module Interconnection
Battery busbars are made from T2Y2 oxygen-free copper (≥98% IACS conductivity) with heat-shrink insulation, ensuring low ohmic losses and reduced temperature rise under operation. The rectangular solid-section design offers a flat, uniform profile with excellent mechanical strength and fatigue resistance, suitable for 600V–1500V energy storage systems and high-current (hundreds of amperes) module interconnections in commercial & industrial (C&I) storage and EV battery packs. The low Joule heating during high-current operation enables well-controlled temperature rise under full-load conditions, effectively mitigating risks of cell swelling, thermal runaway, and other safety hazards.
Made from ≥99.90% T2Y2 copper, this rigid busbar delivers low resistance, low temperature rise, and stable high-current performance. Tin/nickel-plated contacts enhance corrosion resistance, while UL94-V0 flame-retardant heat-shrink insulation provides reliable dielectric protection and short-circuit prevention. CNC precision bending and punching enable compact, accurate assembly. With excellent thermal, vibration, and creep resistance, it is widely used in energy storage systems and EV battery modules.
Key Features
- T2Y2 Solid Copper Construction
High-strength copper conductor with >98% IACS conductivity, excellent vibration resistance, and stable low-resistance connections for 600–1500V EV and energy storage high-voltage busbar systems. - V0 Flame-Retardant Heat-Shrink Insulation
Low-smoke halogen-free EVA/PE insulation provides reliable electrical protection, creepage resistance, and short-circuit prevention. - Wide Temperature Reliability
Operates from -50℃ to 125℃, ensuring durability under vehicle vibration, thermal cycling, and harsh energy storage environments. - Color-Coded Insulation Options
Multiple colors available for clear circuit identification and efficient installation and maintenance. - Full Quality Verification
Batch testing covers conductivity, withstand voltage, temperature rise, and flame retardancy with complete inspection documentation.
| Parameter | Withstand Voltage | RoHS | Flammability Rating |
Temperature Resistance |
Wall Thickness | Conductor Material |
| Values | 4000VDC, 1 min | Qualified | UL94 V-0 | -50~125 °C | 1.0-1.5mm | T2Y2 copper |
The busbar edges are CNC rounded and deburred to prevent insulation damage and reduce the risk of leakage or short circuits. Tin/nickel plating layer provides enhanced protection against moisture and sulfur corrosion, ensuring stable contact resistance after bolted assembly and reliable performance during long-term charge and discharge cycles. The rigid busbar features integrated mechanical support, eliminating additional brackets while enabling compact, organized wiring and improved battery PACK space utilization. Designed for high-density energy storage modules, it is widely used in EV battery systems and commercial & industrial energy storage cabinets.
