Flexible Busbars for EV Battery Packs
High-performance laminated copper busbars engineered for electric vehicle battery systems. Optimized for high current, thermal management, and the demanding requirements of automotive applications.
Key Features
High Current Density
Optimized cross-section design delivers maximum current capacity with minimum weight and volume.
Thermal Management
Laminated construction provides excellent heat dissipation, preventing hotspots in battery systems.
Weight Optimization
Precisely engineered to minimize weight while meeting current and thermal requirements - critical for EV range.
Vibration Resistance
Flexible design withstands automotive vibration and shock without fatigue or loosening.
Compact Design
Low-profile construction fits in tight battery pack spaces where rigid busbars cannot.
Safety Features
Insulation options meet automotive safety standards for high-voltage isolation.
Battery Pack Applications
Prismatic Cell Packs
Flexible connections between prismatic cells in module configurations.
Pouch Cell Packs
Low-profile busbars for connecting pouch cell tabs in series and parallel.
Cylindrical Cell Packs
Interconnects for 18650, 2170, and 4680 cylindrical cell modules.
Module-to-Module
High-current connections between battery modules within the pack.
Common Uses
- Battery module interconnections
- Battery pack main busbars
- BMS (Battery Management System) connections
- Inverter connections
- DC fast charging circuits
- High-voltage junction boxes
- Motor controller connections
- Onboard charger connections
EV-Specific Requirements
Electrical Performance
- Low resistance for minimal power loss
- Low inductance for fast switching
- High current capacity for rapid charging
- Consistent performance across temperature range
Mechanical Requirements
- Vibration resistance (automotive standards)
- Thermal cycling durability
- Compact form factor
- Easy assembly and serviceability
Safety & Compliance
- High-voltage isolation (creepage/clearance)
- Flame retardant materials
- Automotive qualification testing
- Traceability and documentation
Technical Specifications
| Current Rating | 100 A - 2,000 A (continuous) |
| Voltage Class | Up to 1,000 V DC |
| Conductor Material | ETP / OFC Copper |
| Lamination Thickness | 0.1 - 0.2 mm (typical) |
| Operating Temperature | -40°C to +85°C |
| Insulation | Kapton, PET, or Nomex |
| Plating | Nickel or tin (for aluminum welding compatibility) |
| Standards | ISO 6469, IEC 61851, SAE J1772 |
Custom Design Services
Every EV battery pack is unique. Our engineering team works with you from concept to production to develop flexible busbar solutions that meet your exact requirements.
- Design consultation and optimization
- Thermal and electrical analysis
- Prototype development
- Testing and validation support
- Production scaling
Ready to discuss your EV project?
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Partner With Us for Your EV Project
From prototype to mass production, we support EV manufacturers with reliable, high-performance flexible busbar solutions. Contact us to discuss your requirements.
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