Flexible Busbar Heat-Shrink Insulated Copper-Aluminium Welded Battery Connector
Flexible Copper Busbar designed for energy storage systems and EV battery applications, manufactured from high-conductivity T2 copper laminated strips with a 1060 aluminium terminal ultrasonically welded on one end. Featuring heat-shrink tubing and braided sleeve dual insulation, it provides excellent conductivity, vibration absorption, assembly tolerance compensation, and reliable insulation performance for high- and low-voltage connections in battery modules, PACK systems, and energy storage cabinets.
Key Manufacturing Processes
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Flexible Copper Busbar Forming: Manufactured from multiple layers of T2 copper strips laminated and welded together, ensuring a uniform conductor cross-section, strong current-carrying capability, and excellent flexibility for bending applications.
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Copper-Aluminium Joint Technology: The aluminum terminal is ultrasonically welded to the flexible copper busbar, creating a solid-state metallurgical bond with low contact resistance, no oxidation layer, and long-term connection stability, ideal for high-volume new energy applications.
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Insulation Protection: The conductor is fully insulated with flame-retardant heat-shrink tubing and an abrasion-resistant braided sleeve. Customized insulating covers are added to the aluminum terminals for enhanced terminal isolation and protection against creepage and short-circuit risks.
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Surface Finishing: Tin or nickel plating is available to improve oxidation and corrosion resistance, while the braided sleeve further enhances wear resistance and bending durability.
Product Advantages
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Copper-Aluminium Transition Design: Combines copper and aluminium terminals to meet dissimilar metal connection requirements between battery aluminium poles and copper busbars, effectively reducing galvanic corrosion risks.
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Low Resistance & Stable Current Carrying: Ultrasonic welding ensures an oxidation-free, void-free bonding interface with extremely low contact resistance. High-conductivity copper foils provide stable current transmission with low temperature rise under high-current operation.
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Dual Insulation Protection: Flame-retardant heat-shrink insulation combined with terminal insulating covers and a braided protective sleeve delivers enhanced protection against short circuits, creepage, and mechanical wear.
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Flexible & Vibration Resistant: The laminated flexible copper structure absorbs vibration and installation stress, reducing the risk of cracking or poor contact caused by rigid connections, ideal for EV battery packs and energy storage systems.
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Highly Customizable: Available in customized conductor sizes, lengths, hole patterns, bending angles, and plating options to suit various battery modules, ESS cabinets, and electrical equipment requirements.
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Reliable Quality & Compliance: RoHS-compliant materials and production under IATF 16949 quality standards ensure high product consistency, traceability, and long-term reliability.
Applications
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Flexible copper-aluminium connections for EV battery cells, battery modules, and PACK systems
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Busbar and battery cluster connections in residential and commercial energy storage systems (ESS)
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Flexible busbar transition connections in power distribution cabinets and switchgear
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High-current flexible conductive connections in photovoltaic inverters and UPS systems
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Electrical connections requiring vibration absorption or displacement compensation in industrial automation equipment and motor controllers
