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Solid Copper Busbar
Battery Bus Bar Connections are critical interface components that enable electrical continuity between battery cells, modules, and external circuits. They serve as the vital link that maintains stable power flow while ensuring mechanical robustness and electrical safety. Typically manufactured from high-purity copper or copper alloys, these connectors often include insulating materials like PVC or heat shrink tubing to prevent accidental short circuits and enhance durability in demanding environments such as electric vehicles and energy storage systems.
Production involves precision engineering steps:
Selection of premium oxygen-free or tinned copper to guarantee excellent conductivity.
Utilization of CNC machinery for accurate cutting, bending, and hole punching tailored to each design.
Surface treatments including tin plating or anti-corrosion coatings for long-term reliability.
Application of high-grade insulation materials such as flame-retardant PVC sleeves or heat shrink tubing to improve safety.
Comprehensive testing procedures ensuring electrical performance and mechanical integrity under vibration and temperature variations.
These connectors find wide use across multiple sectors:
High-performance Electric Vehicle (EV) battery packs enabling secure cell connections.
Large-scale Energy Storage Systems (ESS) requiring reliable power transfer.
Industrial and commercial battery banks used in backup power solutions.
Power distribution units (PDUs) where flexible and safe busbar connections are needed.
Telecommunication and uninterruptible power supply (UPS) systems demanding high durability.
Superior electrical conductivity through carefully selected copper materials.
Reliable flame retardant insulation to minimize fire hazards.
Precision fabrication ensuring tight tolerances and seamless fit.
High resistance to corrosion and mechanical wear via specialized surface coatings.
Compliance with global standards such as RoHS and UL, ensuring environmental safety and product reliability.
Designing effective busbar connectors requires:
Accurate calculation of current ratings to define copper thickness and cross-section.
Custom shaping and hole placement to accommodate specific battery configurations.
Choosing insulation materials compatible with operational voltages and temperature ranges.
Engineering for mechanical durability to withstand vibrations and thermal cycling.
Ensuring ease of assembly and maintenance in final battery pack installation.
At G and N Fortune Limited, we offer tailored solutions including:
Fully customized dimensions and hole patterns based on your technical drawings.
Multiple insulation options: flame-retardant PVC, silicone, or heat shrink tubing.
Surface finishes ranging from tin plating to nickel plating.
Prototype development followed by scalable mass production.
Support for various industry standards and certifications.
Over 15 years of experience specializing in copper electrical connectors.
Cutting-edge CNC and surface treatment technologies to ensure top quality.
Dedicated engineering team assisting with design and custom requirements.
Strict quality assurance processes and international certifications.
Competitive pricing, timely delivery, and excellent customer service worldwide.
Primarily high-quality oxygen-free or tinned copper combined with flame-retardant insulation materials.
Absolutely. We customize sizes, shapes, hole configurations, and insulation to fit your requirements.
They are engineered for robust current carrying capacity tailored to your system’s specifications.
Yes, our connectors meet RoHS, UL, and automotive industry standards.
Prototypes generally take 5–7 days; bulk orders typically 10–15 days, depending on complexity.
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