In new energy vehicles, the design of copper busbars differs significantly from traditional copper busbars, mainly reflected in their flexible structure.
Due to the vibration generated by cars during operation, copper busbars on new energy vehicles need to adopt flexible structures to reduce the potential damage to battery cells and other electrical components caused by this vibration. Stacked copper busbar, also known as laminated copper busbar or copper foil connector, is an efficient and reliable electrical interconnection solution commonly used in new energy vehicles.
Laminated copper busbars are composed of multiple layers of strip-shaped copper foils or copper sheets, which are pressed and welded at both ends using a polymer diffusion welding machine to form a hard connection. The middle part remains flexible and can be easily bent and twisted.
This design enables the laminated copper busbars to effectively absorb and disperse vibration energy during vehicle operation, thereby improving the overall driving safety of the vehicle.
Let's understand the difference between new energy vehicle copper busbars and traditional copper busbars.
1. Usage environment: Copper busbars for new energy vehicles are mainly used for battery packs, motor controllers, etc. in electric vehicles, while traditional copper busbars are mainly used for general power equipment such as distribution cabinets, switchgear, etc.
2. Performance: Copper busbars for new energy vehicles need to have good electrical conductivity, thermal conductivity, corrosion resistance, and a certain degree of bending and mechanical strength to meet the requirements of electric vehicles in harsh environments such as high current, high voltage, and high temperature. The performance requirements for traditional copper bars are relatively low.
3. Manufacturing process: Copper busbars for new energy vehicles have different manufacturing processes due to their special usage environment and performance requirements. For example, copper busbars for new energy vehicles usually need to be manufactured through high-precision cutting, bending, stamping and other processes to ensure their accuracy and quality. The manufacturing process of traditional copper bars is relatively simple.
4. Raw material selection: Copper busbars for new energy vehicles usually choose high-purity and highly conductive copper raw materials to meet their high-performance usage requirements. The selection of raw materials for traditional copper busbars is relatively flexible, and different copper materials can be chosen according to actual needs.
In summary, the main difference between new energy vehicle copper busbars and traditional copper busbars lies in their usage environment and performance requirements, which also determine their differences in manufacturing processes and material selection.
