Copper Tinned Busbar
Copper tinned busbar is a conductive component obtained by tin plating surface treatment on the basis of copper busbar. It is made of high-purity copper as the substrate, and after cutting, stamping, bending and other forming processes, a tin layer is formed on the surface through electroplating. It is widely used in new energy electrical systems as a backbone conductor for current collection and distribution.
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Product Introduction
Copper tinned busbar is a high-performance conductive component made from high-purity T2 copper substrate through precision machining and customized tin plating process. It is the core component for current collection, distribution, and connection in electrical equipment. Different from bare copper bars, tin plated copper busbars use tin layer coating technology to significantly improve oxidation resistance, corrosion resistance, and wear resistance while retaining the excellent conductivity of copper substrates. At the same time, they also take into account insulation protection and installation convenience. They are the preferred solution for high-end electrical systems such as new energy electric vehicles, photovoltaic energy storage, power appliances, and rail transit.
Application scenarios
New energy vehicle battery pack
Copper tinned busbar is used for series, parallel, and output pole connections between modules to solve the problems of heating and vibration loosening at connection points under high current. The tin plating layer can effectively resist the corrosion of electrolyte volatiles and humid environments, ensuring the connection stability of the battery system throughout its entire life cycle.
01
Thin film capacitor lead out terminal
Tin plated bus bar is used as an electrode to lead out copper bars in EV/HEV thin film capacitors, requiring low inductance, low resistance, and stable high-frequency performance. The tin plated surface is conducive to ultrasonic welding or laser welding with capacitor terminals, forming a reliable connection with good consistency, low contact resistance.
02
New energy photovoltaic energy storage system
Used for combiner boxes, energy storage converters (PCS), battery cluster combiner cabinets, to solve the problems of salt spray resistance and long-term flow reliability in outdoor environments. Busbars tinned copper are less likely to produce copper green under temperature differences between day and night and condensation conditions, significantly reducing the risk of local overheating.
03
Distribution cabinets and switchgear
HDHC tinned copper busbars are used for the main busbars of low and medium voltage distribution cabinets, replacing bare copper bars to reduce oxidation risks. The tin plating layer improves the consistency of contact between copper bars and copper/aluminum cable terminals during overlapping, reducing galvanic corrosion caused by material potential differences.
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Design advantages
Customized styling design:
Busbar coating breaks through the form limitations of standard copper bars, and can customize bending angles, connection end shapes, and size specifications according to the internal space and installation layout of the customer's equipment, achieving seamless fit with the equipment, reducing installation space occupation, and adapting to the development trend of compact and miniaturized new energy equipment.
Integrated assembly design：
The Tin coated copper busbar connection end is reserved with precise bolt holes, which can directly adapt to standard fixtures such as PEM stainless steel nuts and bolts without additional processing, reducing installation difficulty and time costs; At the same time, the integrated design of insulation components and copper busbars avoids insulation layer detachment and displacement, improving operational safety.
Lightweight and high current carrying balance design：
The Flat copper busbar adopts high-purity T2 purple copper substrate. While ensuring current carrying performance, the thickness and width of the copper busbar are precisely controlled through processing to avoid material waste. At the same time, combined with hollow structure optimization (optional), the weight is further reduced to meet the lightweight needs of new energy vehicles, energy storage systems, etc.
customization process
Requirement communication and engineering review
After the customer submits electrical parameters (voltage, current, environmental conditions), mechanical interface drawings, and certification requirements, our engineering team will conduct a systematic evaluation of the Tin plated copper bar's current carrying capacity, temperature rise control, insulation coordination scheme, and mold feasibility, and issue a preliminary technical proposal.
01
Sample production and free support
After confirming the technical solution, we will provide 1-10 free Tinned copper busbar samples (the specific quantity depends on the complexity of the product). The samples will use the same process and mold standards as mass production to ensure reproducibility in subsequent mass production. All samples will be tested for resistance, conductivity and insulation performance before delivery to ensure they fully meet your engineering requirements.
02
Customer testing and validation
The customer verifies the samples under actual working conditions such as loading (or installation), pressure resistance, temperature rise, salt spray, etc. We provide necessary technical cooperation and failure analysis support during the verification process to ensure that the Tinned copper flat bar meets the requirements for on-site use. Our engineering team will also provide timely feedback and optimization suggestions based on your test data.
03
Batch delivery and production cycle
After the mold of the Copper tinned busbar is confirmed and locked by the customer, it enters the mass production stage. The regular order delivery cycle is 7-10 days. If it includes newly opened stamping molds and tooling manufacturing, the sample delivery cycle is 10-20 days. We maintain strict process control throughout production to guarantee consistent dimensions, plating quality, and performance for every batch.
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contact us
Xiamen Apollo Stamping Welding Technology Co., Ltd is a professional service provider for new energy metal processing solutions. We can help you accurately match your needs and maintain the bottom line of device safety. Welcome to consult us.
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