New energy vehicle power conduction laminated insulated flexible copper busbar, copper busbar insulated terminal
New energy vehicle power conduction laminated insulated flexible copper busbar
S$2.50
H1: New Energy Vehicle Power Conduction Laminated Insulated Flexible Copper Busbar & Insulated Terminal
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High-performance EV flexible laminated copper busbar with insulated terminals. 100A-2800A, 1500V DC, UL94 V-0. For battery packs, inverters & motors.
Product Overview
The New Energy Vehicle Power Conduction Laminated Insulated Flexible Copper Busbar is a next-generation high-current connector designed for electric vehicle (EV) and hybrid electric vehicle (HEV) powertrain systems. Manufactured from multilayer T2 pure copper foils (≥99.9% purity) and covered with a high-temperature, flame-retardant insulation layer, this copper busbar insulated terminal assembly provides superior electrical conductivity, mechanical flexibility, and long-term reliability under harsh automotive conditions.
By replacing traditional solid copper bars or heavy cables, our laminated flexible busbar reduces stress on battery terminals and connectors, absorbs vibration, and simplifies routing in space-constrained battery packs and power electronics.
Key Features
High Current Carrying Capacity – Rated from 100A up to 2800A, suitable for main power circuits in passenger EVs, commercial electric trucks, and energy storage systems.
Low Voltage Drop – Multi-layer laminated construction minimizes skin effect and AC resistance, ensuring efficient power conduction for new energy vehicles.
Excellent Flexibility – The soft copper foil stack endures over 10,000 bending cycles, compensating for thermal expansion and assembly misalignment.
Reinforced Insulation System – Available with heat-shrink tubing (PVC, TPE, EVA/PE) or precision injection-molded plastics (glass-filled PA66). Meets UL94 V-0 flame rating and withstands 3500V AC dielectric strength.
Integrated Insulated Terminal – The copper busbar insulated terminal is compression-molded over the copper end, providing a robust, sealed connection that prevents creepage and short circuits. Bolt-hole patterns or custom terminal geometries available.
Compact & Space-Saving – Flat, bendable shape fits narrow gaps inside battery modules and motor controllers, enabling higher energy density in EV designs.
Applications in New Energy Vehicles
• EV/HEV Battery Packs – Connecting individual battery cells or modules into high-voltage series/parallel configurations.
• Power Distribution Units (PDU) – Main positive/negative busbars inside junction boxes.
• Motor Controller (Inverter) to Drive Motor – Three-phase flexible connections with insulated terminals.
• On-board Charger (OBC) & DC-DC Converter – High-current power transmission between charging modules and the battery.
• Charging infrastructure – Flexible busbars for DC fast-charging stations.