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2026
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01
Technical Requirements and Manufacturing Process for High-Voltage Copper and Aluminum Busbars in Battery Packs
With the rapid adoption of 800V high-voltage platforms in the new-energy vehicle sector, copper and aluminum busbars within battery packs are no longer merely simple conductive components—they have become the “main arteries” for current transmission throughout the entire vehicle. Their performance directly affects the vehicle’s range, fast-charging efficiency, and even its overall safety and reliability.
With the rapid adoption of 800V high-voltage platforms in the new-energy vehicle sector, copper and aluminum busbars within battery packs are no longer merely simple conductive components—they have become the “main arteries” for current transmission throughout the entire vehicle. Their performance directly affects the vehicle’s range, fast-charging efficiency, and even its overall safety and reliability.
01 Technical Requirements
The technical requirements for battery-pack copper busbars encompass five aspects: material, electrical, mechanical, environmental, and safety. This section provides only a general overview of the common technical requirements for copper busbars; specific details should be determined based on the application scenario.
(1) Electrical Performance
There are clear specifications for the materials—for example, the purity of T1/T2 copper bars must be no less than 99.95% and 99.90%, respectively. If aluminum alloys are used, such as... 1070 H12 state Its purity should be ≥99.7%, and H12 indicates the corresponding work-hardened condition.
(2) Process Requirements
The peel strength of the hot-pressed nickel sheet should not be less than 20 N. The surface must remain clean, and defects such as burrs, stains, corrosion, holes, delamination, or obvious wrinkles are strictly prohibited. The surface of aluminum busbars is typically coated with a polymer. PI film The film thickness must be greater than 0.15 mm and able to withstand temperatures above 250℃.
(3) Safety Performance
- Insulation performance: For example, when using heat-shrink tubing as the insulating material, it must meet the following requirements: rated voltage of 1500V, withstand voltage of DC 4380V for 60 seconds, leakage current below 0.1mA, and insulation resistance exceeding 500 MΩ.
- Flame-retardant performance: The insulating material used for the copper busbars in typical battery packs should meet the UL94-V0 flame-retardant rating.
4) Corrosion resistance
The product shall pass the 72-hour neutral salt spray test, with no corrosion or red rust on the surface after the test, and its voltage resistance and insulation performance shall still meet the specifications outlined in the drawings.
02 Manufacturing Process
Take copper busbars as an example: the processing techniques for soft and rigid busbars differ slightly, primarily in their welding and forming methods.
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Jia Chao Technology Group
Address: No. 20, Zhongkeng Farm Road, Shipai Town, Dongguan City
Phone:+86-769-8182 8789