PVC Dipping Nickel Plated Copper BusBar For EV Battery
The PVC Dipping Nickel Plated Copper BusBar for EV Battery is a battery connection busbar with a highly conductive copper conductor base, a nickel-plated surface, and a PVC impregnated insulation layer. It is mainly used for power transmission and convergence in the cell modules, battery packs, and high-voltage distribution units (HV Junction Boxes) of electric vehicle battery systems.
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Product Introduction
The PVC Dipping Nickel Plated Copper BusBar for EV Battery is a core power distribution connection component of electric vehicle battery systems. Its core function is to achieve efficient transmission, distribution, and safe isolation of electrical energy within the battery pack, directly determining the operating efficiency, safety, and lifespan of the EV battery system. The product uses nickel-plated copper as the conductive substrate and PVC as the insulating impregnation layer, adapting to the high-voltage, humid, compact, and frequently vibrating operating conditions of EV battery systems. Its core indicators, such as conductivity, insulation, and environmental resistance, are optimized to meet the engineering requirements of the battery system. Furthermore, leveraging the company's full-industry chain advantages and standardized processes, product compatibility, reliability, and consistency are ensured, making it a key component for guaranteeing the stable operation of EV battery systems.
Core Material Selection Principles
Copper Substrate
The core selection criteria are conductivity, mechanical properties, and engineering compatibility. The Plastic Dipping Electric Copper Busbar Custom Made uses ≥99.9% high-purity copper, offering excellent conductivity, reducing power loss, meeting high current requirements, and good bending performance, allowing for compact battery pack installation. It is the optimal conductive substrate for the product.
Nickel Plating
The core selection criteria are corrosion resistance, abrasion resistance, and conductivity compatibility. The Soft Connection Copper Busbar's nickel plating layer uses nickel, which isolates it from environmental corrosion, prevents oxidation of the copper substrate, does not affect conductivity stability, and has good adhesion to the PVC insulation layer, avoiding the risk of interlayer delamination.
PVC Impregnation Material
The core selection criteria are insulation performance, environmental resistance, and flexibility. The PVC impregnation material used in the Plastic Dipping Copper Busbar can withstand 500-2000V high voltage, is suitable for complex outdoor working conditions, has good flexibility and adhesion, and is cost-effective, enabling large-scale production.
Core technical parameters
Conductivity: The Dipping Busbar for Connection's copper substrate has a purity ≥99.9%, and the nickel plating layer thickness is 0.5-2μm. Under standard conditions at 20℃, the resistance per unit length (1 meter) is ≤0.002Ω. High conductivity minimizes power transmission loss, making it suitable for the high current transmission requirements of battery systems.
Insulation: The PVC Coated BusBars has a PVC impregnated insulation layer thickness of 0.8-3mm, a rated withstand voltage of 500-2000V, and an insulation resistance ≥100MΩ. This effectively isolates the live conductor from the surrounding environment, preventing short circuits and electric shock risks, making it suitable for high-voltage operation of battery systems.
Current Carrying Capacity: Closely related to the cross-sectional area of the copper substrate and heat dissipation conditions. Taking a 50 square millimeter copper substrate cross-sectional area as an example, under good heat dissipation conditions at 40℃, the continuous current carrying capacity can reach 250-350A. Product specifications can be selected according to the power requirements of the battery system.
Dimensional Accuracy: Busbar Isolation length, width, and thickness tolerances are controlled within ±0.1-±0.3mm, and bending angle tolerance is ≤±1°, ensuring precise assembly with other components within the battery pack and avoiding poor connections due to dimensional deviations.
Environmental Resistance: The Dip Insulated Busbar can withstand long-term operating temperatures from -40℃ to 125℃, and is resistant to moisture, salt spray, and chemical corrosion, meeting the outdoor and complex operating conditions required for electric vehicles. Its vibration resistance is suitable for mechanical vibrations of 10-2000Hz with an amplitude ≤2mm.
Mechanical Properties: The PVC Dipped Insulated BusBar has a tensile strength ≥200MPa and a bending radius ≥3 times the busbar thickness, capable of withstanding dynamic stresses during battery pack assembly and vehicle operation, ensuring no breakage or insulation layer detachment.
Application areas
EV Pure Electric Vehicle Battery
The Insulated Custom Copper BusBar with PVC Dipping is compatible with battery packs for pure electric passenger vehicles and commercial vehicles, handling power transmission and isolation within the battery pack and related components. It meets high-power, high-voltage, and high-current requirements, ensuring stable operation of the power system.
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HEV/PHEV Hybrid Electric Vehicle Battery
The Insulated Flexible Copper BusBar for Power Battery Pack is compatible with various hybrid electric vehicle battery packs, handling current fluctuations during gasoline-electric switching. It exhibits good stability and vibration resistance, achieving efficient power distribution between the battery and the fuel system, balancing power and energy efficiency.
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New Energy Special Purpose Vehicle Battery
The product is compatible with battery packs for new energy logistics vehicles, sanitation vehicles, and other special purpose vehicles, meeting their characteristics of frequent start-stop operations and complex outdoor working conditions. It is moisture-resistant and vibration-resistant, ensuring continuous and stable operation of the battery system.
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Energy Storage Battery
The Plastic Dipping Copper Busbar is compatible with energy storage systems for electric vehicles and battery swapping stations, handling power transmission and distribution. It meets high-voltage and high-current requirements, exhibits excellent environmental resistance, and achieves efficient integration of energy storage and electric vehicles.
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Our Partners
Having cultivated deep expertise in the field of PVC Dipping Nickel Plated Copper BusBar for EV Battery for many years, we have always been guided by engineering procurement and technology selection needs. Leveraging our group strength, mature production technology, full-industry chain layout, and global service capabilities, we have built solid advantages in four core dimensions: technology adaptability, long-term reliability, manufacturing consistency, and supply risk control. This has become the core foundation for our success in winning industry recognition and deep cooperation. Currently, we have established long-term and stable cooperative relationships with many well-known electric vehicle and new energy vehicle component suppliers. Our stable and excellent product quality, efficient and rapid response capabilities, and professional and comprehensive services have earned the high recognition and widespread trust of all our partners.
Contact Us
If you have any needs regarding the procurement, selection, or customization of PVC Dipping Nickel Plated Copper BusBar for EV Battery, please feel free to contact us. We will arrange a professional team to provide one-on-one service, customize suitable solutions, and ensure stable supply, accurate selection, and efficient procurement.
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