Flexible Aluminium Bus Bars for EV Batteries with PVC-Extruded Insulation
Aluminium busbars for NEV battery packs, enabling cost reduction and lightweight optimization within existing PACK space while maintaining electrical, mechanical, and environmental performance. Flexible welded structure made from 1060 aluminium strips for tolerance absorption and easy installation. Integrated PVC extrusion insulation ensures full insulation protection.
Flexible Extruded Aluminium Busbars are core interconnection components for NEV battery packs, featuring integrated insulation with advantages in lightweight design and cost reduction. Designed to fit existing battery pack structures, they ensure reliable electrical conductivity, mechanical strength, and environmental durability.
Made from 1060 high-purity aluminum laminations with flexible welded construction, the flexible busbars provide excellent tolerance compensation and displacement absorption, accommodating assembly tolerances and supporting automated mass production with easy installation.
The outer PVC extruded insulation delivers dense and uniform coverage with excellent insulation, high/low temperature resistance, aging resistance, high-voltage resistance, and flame retardancy, ensuring long-term safety and reliability in demanding automotive environments.
| Parameter | Insulation Withstand Voltage | RoHS | Flammability Rating | Working Temperature | Insulation Solution | Conductor Material |
| Values | 6KV | Qualified | UL94 V-0 | -40~125 °C | PVC extruded layer | 1060 aluminium sheets |
Extruded Busbar Requirements
- Surface finish: Smooth and clean, free from oil, pores, bubbles, pitting, and cracks.
- Insulation thickness: Uniform extruded insulation without eccentricity, thickness 0.7 ± 0.2 mm.
- Dielectric strength: Withstands 6 kV without breakdown.
- Adhesion strength: Extruded insulation adhesion to copper or aluminium busbar >5.34 × W N (W = busbar width, mm).
Applications
With advantages in lightweight design, high flexibility, and resistance to high voltage and vibration, flexible extruded aluminium busbars are ideal for high-current interconnections in NEV and energy storage systems.
- NEV Applications: Widely used in battery PACK module interconnections, PDU relay and fuse circuits, MCU power module bus connections, as well as high-current applications including fast-charging circuits, OBCs, and DC-DC converters. They offer low impedance under high-frequency operating conditions and excellent high-voltage resistance.
- Energy Storage Applications: Suitable for ESS battery cluster interconnections, rack-mounted module laminated bus systems, PCS DC bus connections, and low-voltage side connections of medium-voltage distribution systems (10kV/35kV), meeting requirements for high safety and large-current transmission.
