Flexible Braided Copper Busbar for New Energy Vehicles - Custom Solutions from China Suppliers & Factory
The Production Processing for Flexible Braided Copper Busbar
- Material Selection
- →Weaving & Forming
- →Cutting & Flattening
- →End Treatment
- →Insulation Protection
- →Inspection & Acceptance
- →Packaging & Warehousing
- →Shipment
Technical Data for Flexible Braided Copper Busbar
| Material | T2 (C11000) Copper Wire (Copper content ≥99.95) |
| Size | Customized |
| Finish | Bare, Tin Plating, Nickel Plating, Silver Plating |
| Single Wire Diameter |
0.05mm (AWG 44) 0.07mm (AWG 41) 0.10mm (AWG 38) 0.12mm 0.127mm (AWG 36) 0.15mm (standard) 0.20mm (AWG 32) 0.25mm 0.254mm (AWG 30) |
| Cross Sectional Area | 1.5mm² – 5000mm² |
| Working Temperature | -50ºC to 120ºC |
| Ampacity | 20A to 1500A |
| Certification | ROHS | CE | REACH |
The Customization For Flexible Braided Copper Busbar
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The following parameters can all be fully customized based on customer requirements:
Busbar Length · Width · Hole Number · Single Wire Diameter · Surface Treatment
Busbar Length · Width · Hole Number · Single Wire Diameter · Surface Treatment
The Busbar Core Application Scenarios For New Energy Vehicles
Flexible braided copper busbars meet the high-voltage and anti-vibration requirements of new energy vehicles and are key components of their power transmission systems. They are widely used in core parts such as battery systems, power drive systems, and charging-related systems.
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1. Power Battery System
- Connection between the battery cell and the module
- The battery pack is connected to the external interface
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2. Battery Pack to External Interface
- Connection between the battery pack and the high-voltage interface of the entire vehicle
- Ensures stable transmission of large currents
- Low-inductance braided structure controls inrush current
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3. Power Drive System
Flexible braided copper busbars are used for the connection of core components such as inverters and traction motors in this field.
Package & Shipping For Flexible Braided Copper Busbar
Frequently Asked Questions (FAQ)
Q
What material is used for the Flexible Braided Copper Busbar?
The busbar is made from T2 (C11000) copper wire with a copper content of ≥99.95%, ensuring excellent electrical conductivity and long-term reliability.
Q
Can the Flexible Braided Copper Busbar be customized to specific dimensions?
Yes. The busbar length, width, hole number, single wire diameter, and surface treatment can all be fully customized based on your specific requirements. Please contact us with your technical drawings or specifications.
Q
What surface finish options are available for the busbar?
We offer four surface finish options: bare copper, tin plating, nickel plating, and silver plating. Each finish offers different levels of corrosion resistance and conductivity performance to suit various application environments.
Q
What is the operating temperature range and current capacity of the busbar?
The Flexible Braided Copper Busbar operates reliably within a temperature range of -50ºC to 120ºC, and supports ampacity from 20A up to 1500A, making it suitable for both standard and high-power applications.
Q
What certifications does the Flexible Braided Copper Busbar comply with?
Our busbars comply with ROHS, CE, and REACH standards, ensuring they meet international environmental and safety requirements for use in global markets.
Q
What are the main application scenarios for Flexible Braided Copper Busbars in new energy vehicles?
They are widely used in new energy vehicles for three key areas: the power battery system (cell-to-module and battery pack connections), the battery pack-to-vehicle high-voltage interface connection, and the power drive system (inverter and traction motor connections). Their flexible, low-inductance braided structure makes them ideal for high-vibration, high-current environments.