China Copper-Aluminum Transition Bar for EV Charging Piles - Reliable Suppliers & Factory Solutions
Product Structure
- Flat Type (Most Common): Copper end (tinned) + aluminum end, with bolt holes for butt connection, suitable for charging modules, rectifier cabinets and cable heads of charging piles, easy to install and disassemble.
- L Type / Right Angle Type: For vertical turning connection, suitable for the internal narrow space layout of charging piles, saving installation space.
- Groove Type / Special Type: Customized according to the internal conductive structure of charging piles, suitable for card slot connection of busbars, ensuring stable connection and avoiding displacement during operation.
Application Scenarios (Charging Piles)
Our copper-aluminum transition bar is widely used in various types of EV charging piles and charging stations, covering all key copper-aluminum connection points of internal conductive components, perfectly matching the current transmission needs of high-power and low-power charging scenarios alike, especially suitable for 800V high-voltage platform DC fast charging piles with high current requirements.
1. DC Fast Charging Piles (High-Power)
- Connection between aluminum busbars and copper terminals of charging modules (most common application, suitable for 60kW–360kW DC piles, and 480kW ultra-fast charging piles)
- Transition connection between aluminum-core power cables and copper terminals of rectifier cabinets (adapting to high-current transmission needs of 800V high-voltage platforms)
- Connection between aluminum busbars and copper conductive parts of charging guns (high-current transmission, reducing overheating risks during fast charging)
- Transition connection between aluminum busbars and copper grounding terminals (ensuring safe grounding, complying with the new national standard for battery safety)
2. AC Charging Piles (Low-Power)
- Connection between aluminum busbars and copper terminals of charging controllers
- Transition connection between aluminum cables and copper terminals of socket outlets
- Connection between aluminum busbars and copper conductive components of leakage protection devices (ensuring charging safety)
3. Charging Stations & Supporting Equipment
- Connection between aluminum busbars of charging station distribution cabinets and copper terminals of feeder cables
- Transition connection between aluminum busbars and copper terminals of energy storage modules in integrated charging stations (balancing conductivity and lightweight)
- Connection between aluminum busbars of cable trays and copper grounding/return wires in charging stations
- Transition connection between aluminum cables and copper terminals of portable charging piles (lightweight and easy to carry, reducing product weight)
Customization Service
We provide professional customization services to meet the specific needs of different charging pile models and power levels, adapting to the internal layout and current transmission requirements of various charging piles:
- Size Customization: Thickness, width, length, and copper layer thickness can be customized according to customer drawings or requirements, matching the current-carrying capacity needs of different power charging piles.
- Structure Customization: Customize flat type, L type, groove type, or other special-shaped structures according to the internal narrow space layout of charging piles.
- Surface Treatment Customization: Adjust tin plating thickness or other surface treatments according to customer requirements, enhancing oxidation resistance and conductivity.
- Standard Customization: Meet the special requirements of different countries and regions (such as European, American, and Asian standards), ensuring compliance with local product quality laws and regulations.
Shipping
Shipping Method
By sea, air, or express (DHL, FedEx, UPS), according to customer needs; choose reliable and experienced shipping companies to avoid product damage during transportation.
Port of Loading
Shanghai, Shenzhen, Guangzhou, or other Chinese ports.
Delivery Time
7–15 working days for standard products; 15–30 working days for customized products.
Frequently Asked Questions
Q
What is a copper-aluminum transition bar and why is it used in charging piles?
A copper-aluminum transition bar is a bimetallic connector that joins copper and aluminum conductors, preventing galvanic corrosion at the contact point. In EV charging piles, it bridges aluminum busbars (used for their light weight and cost advantage) with copper terminals (standard on modules and cables), ensuring safe, low-resistance current transmission across the connection.
Q
Which charging pile power levels are your transition bars compatible with?
Our copper-aluminum transition bars are compatible with a full range of charging pile power levels — from standard 7kW AC home chargers to 60kW–360kW DC fast chargers and 480kW ultra-fast charging piles. They are specifically engineered to handle the high-current demands of 800V high-voltage platform DC systems.
Q
Can you produce copper-aluminum transition bars in custom shapes or sizes?
Yes. We offer full customization of thickness, width, length, copper layer thickness, and structural form (flat, L-type, groove-type, or other special-shaped profiles). Customers are welcome to provide drawings or detailed specifications, and we will manufacture to match the exact internal layout and current-carrying requirements of their charging pile models.
Q
What surface treatment is applied to the copper end, and can it be changed?
The copper end is standard tin-plated to prevent oxidation and improve contact conductivity. Tin plating thickness can be adjusted upon request, and alternative surface treatments can be arranged to meet specific environmental or performance requirements. Please let us know your specifications when placing an inquiry.
Q
Do your products comply with international standards for different markets?
Yes. We support standard customization to meet the regulatory and quality requirements of different regions, including European (CE/IEC), North American (UL/ANSI), and Asian standards. This ensures the products supplied are fully compliant with the local laws and certifications required in your target market.
Q
What is the typical lead time and how are the products shipped internationally?
Standard products are shipped within 7–15 working days; customized orders require 15–30 working days. We ship by sea, air, or express courier (DHL, FedEx, UPS) based on your preference and urgency. Loading ports include Shanghai, Shenzhen, Guangzhou, and other major Chinese ports. We work with experienced logistics partners to ensure safe delivery.