New Energy Aluminum Busbar Sheet
✦ Brand: Senloong
✦ Product Name: Busbar Connector
✦ Conductor material: High quality copper/aluminum material, supports customization on demand
✦ Surface treatment: Optional options include nickel plating, matte tin plating, zinc plating, and chrome plating
✦ Core applications: New energy electric vehicles ⊙ Electric motorcycles Various power supply systems
✦ Quality Certification: ISO9001:2015 Quality Management System Certification
Products Description
Product Overview
Our OEM new energy aluminum busbar is a key conductive component made of high-purity and highly conductive aluminum alloy, manufactured through advanced precision machining and surface treatment processes.
It is developed specifically to meet the demanding requirements of modern high voltage and high current applications, aiming to replace traditional copper bars and achieve significant lightweighting, cost optimization, and design flexibility while ensuring excellent electrical performance.
It is the ideal choice for your power system integration.
Product Parameters
|
Product Type |
Customized Aluminum Bar |
|
Material |
High purity aluminum alloy (such as 1070, 1060, 3003, etc.) |
|
Size&Thickness |
Customize size&thickness according to requirements |
|
Shape |
Customize the shape according to your needs |
|
Surface treatment |
Bare aluminum, tin plating, nickel plating, silver plating, anodizing (selected according to weldability, corrosion resistance, and contact resistance requirements) |
|
Thickness range |
0.5mm -8.0mm (or customized according to requirements) |
|
Width range |
up to 400mm (or customized according to requirements) |
|
Production process |
precision stamping, laser cutting, CNC bending, welding, riveting, etc |
Core advantages and characteristics
✦ 1. Excellent electrical performance
High conductivity: Made of high-quality aluminum alloy, the conductivity can reach ≥ 58% IACS, ensuring efficient power transmission, reducing energy loss and heat accumulation.
Low impedance and low inductance design: Through optimized structural design and precise bending processes, the line impedance and parasitic inductance are effectively reduced, improving system efficiency and stability.
✦ 2. Excellent lightweighting and cost-effectiveness
⊙ Lightweight: With the same conductivity, aluminum has a density only about one-third that of copper, achieving a weight reduction of up to 60%. This is crucial for improving the range of electric vehicles and the power density of energy equipment.
Cost advantage: The raw material cost is significantly lower than copper, providing you with more competitive solutions without sacrificing performance and reliability.
✦ 3. Top level reliability and security
Excellent thermal management: Good thermal conductivity helps to dissipate heat quickly, coupled with appropriate surface treatment, it can withstand high working temperatures, ensuring stable operation of the system in high-temperature environments.
High current carrying capacity: Accurate cross-sectional area design and material selection ensure that the busbar can safely carry continuous currents of hundreds to thousands of amperes.
Strong corrosion resistance: Provides multiple surface treatment options (such as tin plating, silver plating, anodizing, etc.) to effectively resist oxidation and electrochemical corrosion, extending service life.
✦ 4. Unparalleled design and customization flexibility
Integrated complex structure: supports laser cutting, CNC stamping, precision bending and other processes, can integrate multiple discrete connectors into a complex integrated component, reduce connection points, and improve system integration and reliability.
⊙ OEM/ODM support: We provide comprehensive customized services and can accurately manufacture busbars of any shape, size, and connection method based on your 3D drawings, samples, or specific electrical/mechanical requirements.
Flexible connection solution: can integrate bolt holes, ultrasonic welding positions, laser welding grooves, etc., making it convenient to connect with battery modules IGBT, Capacitors and other components are quickly and securely connected.
✦ 5. Strict quality control
From raw material storage to finished product delivery, a strict quality inspection system is implemented throughout the entire process, including testing for dimensional accuracy, conductivity, surface insulation withstand voltage, etc., to ensure that every product meets the highest industry standards.
🚀 Application field
✦ Electric vehicles: internal connection of battery pack, connection between modules, motor drive unit, PDU (power distribution unit).
✦ Energy storage system: internal connections of the battery rack and internal bus of the PCS (inverter).
✦ Charging facilities: Internal high-power module connection of DC fast charging pile.
✦ Renewable energy sources: photovoltaic inverters, wind power inverters.
✦ Industrial equipment: Frequency converters and UPS have different power outages.
🔧 We provide clear and efficient OEM/ODM customization services to ensure a seamless transition from concept to mass production.♻️
1. Requirements communication and analysis
We will have in-depth discussions with you on project requirements, including electrical parameters, structural space, application environment, and budget goals.
2. Scheme design and review
Our engineering team will conduct 3D structural, electrical, and heat dissipation simulation design based on your needs.
Output detailed design proposals, drawings, and technical parameters, and jointly review and confirm with you.
3. Quotation and Agreement Signing
After the plan is confirmed, we will provide transparent product quotations and production cycle estimates.
Both parties have reached an agreement and signed a cooperation agreement.
4. Quick sampling and testing
We provide fast prototyping services to produce physical samples for verification.
The samples will undergo strict testing for size, electrical performance, and reliability.
5. Sample confirmation and optimization
We will send you the tested samples for installation verification.
Based on your feedback, make final optimizations and adjustments.
6. Batch production and delivery
After sample confirmation, start the standardized batch production process.
Perform full process quality monitoring to ensure product consistency and timely delivery.
✦ Advanced Sheet Metal Solutions - Proven Globally, Trusted Locally. ✦
For years, our products have been showcased at the world's leading industrial trade fairs, engaging with global industry leaders and building partnerships across international markets.
▌Why Choose Us?
Global Insight, Local Implementation:
We integrate worldwide innovations into precision-engineered solutions tailored to your needs.
Established International Presence:
Our active participation in major expos underscores our commitment to excellence and technological advancement.
Trusted by Industry Pioneers:
Join a growing network of leaders who rely on our expertise in fabrication and reliability.
FAQ
Q1: The conductivity of aluminum is not as good as copper, why choose aluminum busbar?
Although the conductivity of aluminum is about 60% that of copper, the same current carrying capacity can be achieved by increasing the cross-sectional area. Its core advantages lie in extreme lightweighting (up to 60% weight reduction) and significant cost savings, with a high overall cost-effectiveness, making it very suitable for weight and cost sensitive new energy applications.
Q2: How do you ensure the reliability and corrosion resistance of the aluminum busbar connection?
We ensure this through professional surface treatment processes such as tin plating, silver plating, etc. This coating can effectively prevent oxidation, improve contact resistance, and provide excellent welding and crimping performance, thereby ensuring long-term stability and corrosion resistance of the connection point.
Q3: What is the delivery cycle for customizing a busbar?
The cycle depends on the complexity of the design and the number of orders. Usually, the sampling stage takes 5-7 working days, and the mass production stage takes 10-15 working days. For urgent needs, we provide expedited services, which can be negotiated.
Q4: What connection methods do you support?
We support a comprehensive range of connection solutions, including but not limited to laser welding, ultrasonic welding, bolted connections, riveting, and more. We can prefabricate corresponding connection interfaces on the busbar according to your product structure and process requirements.
Q5: How to ensure quality consistency during mass production?
We implement a full process quality control system from raw materials to finished products. Each batch of products will undergo sampling or full inspection of key items such as size, conductivity, insulation withstand voltage, and surface treatment, and a testing report will be issued to ensure that the products always meet the standards.
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