Custom Flexible Copper Busbar for 280Ah LiFePO4 Battery Cells, Laser-Cut Bent T2 Copper Shunt with Nickel Cladding & Heat Shrink Insulation

Product Description

Engineered to Solve Cell Swelling & Terminal Stress in 280Ah Battery Packs

High-capacity 280Ah–314Ah prismatic LiFePO4 cells undergo significant mechanical expansion ("breathing") during charge-discharge cycles. Using rigid busbars on these cells often leads to cracked laser welds, stripped terminal threads, or accelerated cell degradation. Our Custom Flexible T2 Copper Busbarsfeature a precision-formed expansion arch and laminated copper foil core that flexes effortlessly—maintaining a rock-solid electrical connection over 6,000+ battery cycles.

Key Design & Manufacturing Features

• 1. Laser Cutting & CNC Bending for Exact Alignment 
  We utilize high-precision fiber laser cutting and CNC punching to hold hole-to-hole tolerances within ±0.15 mm. Whether you need slotted mounting holes to accommodate pack assembly tolerances or multi-axis Z-bends for row-to-row crossovers, every busbar fits seamlessly onto your module jig.

• 2. Nickel-Clad Pads for Laser Welding or Bolted M6 Studs 

  • For Automated Laser Welding Lines: We metallurgically bond 0.15mm–0.30mm pure nickel strips onto the copper contact pads, preventing brittle copper-aluminum intermetallics and ensuring high-strength laser welds directly onto cell terminals.

  • For Bolted / Stud Terminals: We provide tin-plated or bare T2 copper contact ends with clean, burr-free M6 (6.5mm x 8.5mm slotted) holes for reliable torque retention.

• 3. Heavy-Duty Heat Shrink Sleeve Insulation 
  The flexible laminated midsection is sealed with industrial-grade UL224 / UL94 V-0 heat shrink tubing(available in orange for HV safety, black, red, or blue). Exposed terminal windows are stripped to exact tolerances so they never interfere with laser welding optics or torque wrenches.

Standard 280Ah Pitch Reference & Custom Sizing

Note: Below are our most popular configurations for 280Ah/304Ah/314Ah prismatic cells. All dimensions, hole patterns, and cross-sections can be fully customized to your CAD drawings.

Technical Specifications & Dielectric Ratings