The power battery of new energy vehicles has high current requirements. Ordinary conductive connectors cannot carry such a large amount of current and voltage, while copper bars (copper busbars) are different. They are a high current conductive product with good conductivity, heat dissipation, flexible input and output, good flexibility, adaptability to high voltage and high current, and can be well connected to battery modules.
There are three main ways to connect copper bars in the battery pack of new energy vehicles:
1. Flexible copper busbar connection
Soft copper busbars are made by stacking multiple layers of flat and thin copper foil conductors to prevent corona, and the outer layer is extruded to cover the insulation layer. They have good flexibility and can be easily bent and folded to meet various temperature and insulation requirements. Soft copper busbar connection is a flexible connection between transformers, generator sets, and other large conductive equipment, mainly used for the conductive connection of power battery packs and charging piles, and is currently the most widely used connection method.
2. Hard copper busbar connection
Usually acting as a conductor in the space of a compact battery pack, a long conductor with a rectangular or chamfered (rounded) cross-section, and insulation mainly includes heat shrink tubing, in mold injection molding, immersion molding, and other methods. In addition to copper materials, aluminum bars can also be used for hard connections, playing a role in transmitting current and connecting electrical equipment in circuits.
3. FlatWire copper busbar connection
Used to connect individual battery cells and electrical components such as hybrid electric vehicles and pure electric vehicles, suitable for charging battery connections. It is an alternative to the traditional busbar connection between the main power supply and distribution equipment.
Used to connect individual battery cells and electrical components such as hybrid electric vehicles and pure electric vehicles, suitable for charging battery connections. It is an alternative to the traditional busbar connection between the main power supply and distribution equipment.
After roughly understanding the connection method of copper bars in new energy vehicle battery modules, it is worth delving deeper into the technical parameters of copper bars:
The copper busbar flexible connection used in new energy vehicle batteries, also known as the copper busbar expansion joint, mainly plays a regulating role in reducing and avoiding stress on the joint. By compensating for the displacement caused by thermal expansion and contraction of the pipeline, it ensures safe and normal operation, prevents the copper busbar from breaking, and has a protective effect.
Copper busbar can be divided into two types according to different occasions: busbar and equipment expansion, busbar and busbar expansion. The joint material is mainly selected based on the busbar material, for example, aluminum busbar and copper joint require the use of aluminum copper expansion joints. Generally speaking, copper and aluminum are not suitable for direct bonding. If bonding is necessary in special circumstances, the copper busbar joint needs to be treated with hot tin to prevent electrochemical reactions between aluminum and copper, which may affect product use.
The copper busbar uses T2 red copper conductor and PVC insulation. Compared to other copper materials, T2 red copper has fewer impurities and produces products with low resistance and high copper content. Compared with traditional heat shrink tube technology, PVC insulation material has better insulation and pressure resistance, longer service life, smooth, beautiful, and more textured products.
YIPU Metal copper busbars are widely used for series installation between new energy vehicle battery modules, suitable for electrical engineering such as high and low voltage appliances, switch contacts, distribution equipment, bus ducts, and high current electrolytic smelting engineering. YIPU Metal can design various copper busbar solutions according to customer needs, including extrusion molding, immersion molding, and hot plastic pipe installation.If you need it, please contact us to provide you with suitable copper busbar solutions.
