Custom Flexible Copper Busbar, PVC Insulated Laminated Copper Shunt With Nickel Cladding For EV Battery Pack

Product Description

Engineered for High-Voltage EV Battery Packs & Energy Storage Systems

In modern lithium-ion battery modules, rigid busbars can transfer harmful mechanical stress to cell terminals during thermal cycling and road vibration. Our Custom PVC Insulated Flexible Copper Busbars solve this challenge by combining high-purity laminated copper foil with precision nickel-clad contact pads and heavy-duty PVC dip insulation.

Core Manufacturing Advantages

• 1. Advanced Polymer / Molecular Diffusion Welding 
  Unlike traditional riveted or brazed shunts, our laminated copper foils undergo solid-state molecular diffusion welding under controlled vacuum, heat, and pressure. This creates a monolithic, low-resistance contact area with zero air gaps, preventing localized overheating and ensuring consistent current distribution across every foil layer.

• 2. Seamless Nickel Cladding for Dissimilar Metal Joining 
  To simplify your automated battery pack assembly, we integrate pure nickel strips (0.1mm–0.5mm thick) directly onto the copper contact pads. This eliminates galvanic corrosion and enables clean, spatter-free laser welding or ultrasonic bonding directly to prismatic or cylindrical cell terminals.

• 3. High-Dielectric PVC Dip Coating 
  Our automated PVC plastisol dipping process forms a tightly bonded, pinhole-free insulating jacket around the flexible section. It resists abrasion, automotive fluids, and moisture while meeting UL94 V-0flame retardancy standards.

Technical Specifications & Dielectric Ratings

Ampacity Reference Chart

Note: Current ratings below are based on an ambient temperature of 30°C and a maximum temperature rise (ΔT) of 35°C in free air. Custom cross-sections can be engineered for higher ampacity.

Primary Applications

• EV & HEV Battery Modules: Cell-to-cell flexible interconnects, module-to-module jumpers, and BMS voltage/temperature sensing busbars.

• Energy Storage Systems (ESS): High-current rack-to-rack flexible connections for utility-scale and commercial BESS.

• Power Electronics & Inverters: IGBT module connections, traction inverters, and DC-DC converters.

FAQ

A: Pure copper has high reflectivity to infrared fiber lasers and forms brittle intermetallic compounds when welded directly to aluminum or steel cell terminals. Bonding a pure nickel (N6 / Ni200) cladding layer onto the copper contact pad absorbs laser energy efficiently, eliminates weld spatter, prevents galvanic corrosion, and ensures consistent, low-resistance laser or ultrasonic welds.

A: Molecular diffusion welding fuses multiple layers of thin copper foil (0.05mm–0.20mm) directly together under vacuum, heat, and pressure without adding solder, silver brazing alloys, or mechanical rivets. This creates a solid, monolithic terminal with zero intermediate contact resistance, superior current-carrying capacity, and high mechanical strength that will not loosen under extreme automotive vibration.

A: PVC plastisol dip coating creates a seamless, custom-molded insulating jacket that conforms tightly to complex 3D bends without wrinkles or air gaps. It offers superior abrasion resistance, chemical resistance against battery electrolytes and automotive fluids, and achieves a UL94 V-0flame-retardant rating with dielectric withstand voltage up to 3,000V–5,000V AC.

A: Because the conductor is composed of thin, unbonded copper foil layers in the flexible middle section, it acts as a mechanical stress absorber. It easily accommodates ±2 mm to ±10 mm of dimensional tolerance, thermal expansion, and lithium-ion cell swelling (breathing) over thousands of charge-discharge cycles without transferring fatigue stress to the battery terminals.

A: Yes. We customize every dimension to your 2D/3D CAD drawings (STEP, DWG, DXF, PDF). Standard pure nickel cladding thickness ranges from 0.10 mm to 0.50 mm depending on your laser welding penetration depth, and we maintain tight tolerances (±0.2 mm) on the exposed weld window length.

A: Every batch undergoes strict quality validation under IATF 16949 standards, including 100% Hi-Pot (dielectric withstand) testing at 3,000V–5,000V AC, micro-ohm resistance verification, dimensional inspection via CMM/optical projectors, and weld peel-strength testing upon request.