Aluminum Flat Busbar
Aluminum Flat Busbar is a key conductive component in power systems, energy storage systems, new energy vehicles, rail transit, photovoltaic inverters, and other industries. It has become an ideal alternative material to copper busbars due to its excellent conductivity, light weight, high strength, processing flexibility, and cost-effectiveness. Our company provides aluminum busbar products with various specifications and processes, which are suitable for different projects and structural requirements, and widely serve international B2B engineering customers and system integrators.
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Product Introduction
Products Description
In the power transmission and distribution system, the aluminum flat busbar is the "nerve center" of power conduction, and its performance directly affects the energy efficiency, stability, and safety of the entire system. We have been focusing on the precision manufacturing of aluminum products for many years. The aluminum flat busbars we produce have been widely used in new energy power stations, rail transportation, industrial power distribution, and other fields with their excellent conductivity and reliable structural quality, and have become the preferred partner of many power engineering companies and equipment manufacturers at home and abroad. The following is a detailed explanation of the five core advantages of this product to help you make professional purchasing decisions.
Core application scenarios: enabling efficient energy transmission
| Lithium battery system (ESS/EV) | Series/parallel connection between modules, total positive and negative poles of Pack, replacing traditional wiring harness solutions. Advantages: lightweight, low internal resistance, compact space, and friendly to automated assembly. |
| High-voltage power distribution for new energy vehicles | PDU (power distribution unit), OBC (on-board charger), DCDC connection - Advantages: strong current carrying capacity, good shock resistance, and excellent EMI shielding performance. |
| Industrial power distribution and frequency conversion system | Inverter cabinet, UPS uninterruptible power supply, bus duct connector - Advantages: cost-effective, easy to maintain, and clear heat dissipation path. |
| Data center power distribution | server rack bus, high-voltage direct current (HVDC) connection - Advantages: save channel space, reduce transmission loss, and support modular expansion. |
| Renewable energy power generation system | photovoltaic inverter, wind power converter internal connection - Advantages: strong weather resistance, resistance to current shock, and low life cycle cost. |
Five core selling points
High conductivity | Reduce power loss by 30%
Technical parameters: The conductivity of 6061-T6 aluminum alloy reaches 61% IACS, which is better than ordinary aluminum (50-55% IACS), close to the conductivity efficiency of Copper Grounding Busbars, and can reduce power transmission loss by 30%.
Application verification: Under a current load of 1000A, the temperature rise is only 35K (lower than the industry standard 50K), ensuring long-term stable operation.
Scenario adaptation: Suitable for high-frequency power equipment such as medium-frequency power supplies and photovoltaic inverters to reduce energy waste caused by resistance heating.
01
Lightweight structure | Weight reduction of more than 50%
Material properties: The density of aluminum is only 2.7g/cm³, and the weight is only 1/3 of that of Grounding Copper Busbars. The weight of a single 100×10mm 6061 aluminum bus bar is about 1.2kg/m, which reduces transportation and installation costs.
Space optimization: Flat design reduces the space occupied by bus duct by 30%, supports high-density equipment layout, and is especially suitable for confined spaces (such as ship cabins and data centers).
Installation efficiency: Modular structure with snap-on connectors shortens installation time by 50% and reduces labor costs by 40%.
02
Excellent heat dissipation performance | Temperature rise controlled within 40K
Heat dissipation design: The surface is stamped with heat dissipation fins, and the heat dissipation area is increased by 50% compared with traditional 6101 Aluminium Flat Busbars. With the anodized layer (thermal conductivity 237W/m·K), the operating heat can be quickly discharged.
Test data: At an ambient temperature of 40℃ and a load of 800A, the surface temperature rise is only 38K, which is far lower than the IEC standard (≤70K).
Safety guarantee: Passed the UL 1557 thermal stability test, no deformation, no insulation aging risk.
03
Super corrosion resistance | Maintenance-free for more than 10 years
Surface treatment: Anodized layer thickness 10-20μm, hardness ≥HV300, salt spray corrosion resistance (ASTM B117) up to 2000 hours without rust.
Environmental adaptability: It can be used normally for more than 15 years in coastal areas (salt spray concentration 0.05mg/m³) without additional anti-corrosion treatment.
Special scenarios: Support nickel plating, silver plating, and other processes to meet the needs of strong corrosion environments (such as chemical plants and offshore platforms).
04
Precision manufacturing process | Error ≤0.05mm
Processing accuracy: Using CNC five-axis machining center, the tolerance of key dimensions (such as hole position and margin) is controlled at ±0.05mm, and the flatness is ≤0.1mm/m.
Quality control: Full process ISO 9001 certification, each batch provides a three-dimensional inspection report and material certificate (SGS traceable).
Customization capability: Supports special-shaped bus bar aluminium processing, with the maximum size reaching 1200×100×10mm, meeting the customization needs of high-current aluminium flat busbar for switchgear ducts.
05
Innovation and application of manufacturing technology
High-precision stamping and forming: High-precision stamping and forming technology is used to ensure that each Aluminum Busbar Electrical Power Connector meets the highest quality standards. Through advanced equipment, busbars of various shapes can be accurately manufactured to maintain consistency across all production batches.
Automated manufacturing process: The automated manufacturing process ensures the consistency and accuracy of each Customized Aluminium busbar throughout the production process. This not only improves production efficiency, but also ensures the stability of product quality.
Customized production: Customized aluminum alloy flat busbar solutions are provided according to the specific needs of customers. From size, performance shape, it can be adjusted according to specific project requirements to meet the needs of different application scenarios.
Advanced heat treatment technology: The mechanical properties of 6101 aluminum bus bars are optimized through advanced heat treatment technology. This helps to improve the strength and durability of the busbar, enabling it to maintain good performance in various harsh environments.
Strict quality inspection system: A strict quality inspection system is implemented throughout the manufacturing process. From raw material inspection to finished 6101 t61 aluminum bus bar testing, every link is strictly controlled to ensure that the final product meets the highest industry standards.
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