Products / Copper Busbar Solutions
Copper Busbar Solutions
Precision-manufactured copper busbars including rigid, flexible, and laminated types with nickel/tin plating. Engineered for high-current power distribution in EV battery packs, energy storage systems, and industrial equipment.
Rigid Copper Busbar - Nickel Plated
Custom-fabricated rigid copper busbars with electroless nickel plating. CNC machined to exact specifications.
Key Specifications
MaterialT2 Copper (Cu ≥ 99.9%)
PlatingElectroless Nickel 5-15 µm
Conductivity≥ 97% IACS
Thickness Range1.0-10.0 mm
Width Range5-200 mm
StandardsGB/T 5585, IEC 61439
Features
- T2 copper (99.9% purity)
- Electroless nickel plating 5-15µm
- CNC machined to ±0.1mm
- Custom shapes: straight, L, U, Z bends
- Insulation sleeving available
Battery Module InterconnectionPower Distribution CabinetsSwitchgearEV Power DistributionInverter DC Links
Flexible Copper Busbar - Laminated
Multi-layer laminated flexible copper busbars for vibration absorption and thermal expansion compensation in EV packs.
Key Specifications
MaterialT2 Copper Foil, 0.1-0.3 mm/layer
PlatingTin or Nickel
Cross Section10-1000 mm²
Flex Life> 100,000 cycles
Temperature Range-40°C to +150°C
StandardsIEC 61439, RoHS
Features
- Multiple thin copper foil layers
- Diffusion welding at contact areas
- 3D flexibility for complex routing
- Low inductance design
- Heat shrink / epoxy insulation
EV Battery Module ConnectionsPower ElectronicsRail Traction InvertersWind Power Converters
Laminated Busbar Assembly
Multi-layer insulated laminated busbar assemblies with ultra-low inductance for high-power IGBT/SiC module connections.
Key Specifications
Layer Count2-8+ layers
ConductorT2 Copper, 0.5-3.0 mm
Inductance< 10 nH (typical)
Voltage RatingUp to 4500V DC
Temperature ClassClass H (180°C) or Class C
StandardsIEC 61439, IEC 62477
Features
- Multi-layer for low inductance
- Polyester/Polyimide insulation
- Capacitive coupling for EMI reduction
- Laser-cut precision layers
- Partial discharge free design
IGBT/SiC Power ModulesTraction InvertersIndustrial Motor DrivesGrid-Tie Inverters
Insulated Laminated Busbar Assembly
Insulated laminated busbar with PET/PI/Kapton insulation layers for high-voltage power distribution. Ultra-low inductance design for IGBT and SiC power module connections in ESS and EV inverters.
Key Specifications
Layer Count2 to 8+ layers
ConductorT2 Copper, 0.5-3.0 mm
InsulationPET, PI (Kapton), Nomex
Voltage RatingUp to 4500V DC
StandardsIEC 61439, IEC 62477, UL 1558
Features
- PET / PI (Kapton) / Nomex insulation
- 2-8+ layer construction
- Ultra-low inductance < 10nH
- Partial discharge free design
- Surface mount and press-fit options
IGBT/SiC Power ModulesESS Power Conversion SystemTraction InvertersGrid-Tie Inverters
Frequently Asked Questions
What types of copper busbars do you manufacture?
We manufacture rigid nickel-plated copper busbars, flexible laminated copper busbars, insulated laminated busbar assemblies, and custom-shaped busbars (L, U, Z bends). All are CNC machined from T2 copper (99.9% purity) with electroless nickel, tin, or silver plating. Visit our Copper Busbar Solutions page for technical specifications.
Can you customize busbar dimensions and plating?
Absolutely. We offer full customization of busbar dimensions (thickness 1.0-10.0mm, width 5-200mm), shape (straight, L-bend, U-bend, Z-bend), hole patterns, and surface plating (nickel 5-15µm, tin, silver). Send us your drawing or specifications for a quotation within 24 hours.
What is the difference between rigid and flexible busbars?
Rigid busbars are solid copper bars ideal for fixed geometry applications with high current density. Flexible laminated busbars are made from multiple thin copper foil layers, providing 3D flexibility for vibration absorption and thermal expansion compensation — ideal for EV battery pack interconnections. See our blog post 'Copper Busbars vs. Cable Harnesses' for a detailed comparison.
Where is PowerConnect Technologies located?
Our headquarters and 25,000 m² manufacturing facility is located in Shenzhen, Guangdong, China (No. 88, Xingye Road, Bao'an District). We have 12 automated production lines, 500+ employees, and export to 30+ countries worldwide. Visit our Factory Tour page for a virtual walkthrough.
What quality certifications does your factory hold?
We hold ISO 9001:2015, IATF 16949:2016, ISO 14001:2015, and our products are certified to UL, TUV, CE, RoHS, and REACH standards. We implement a 5-stage quality control process from incoming material inspection to final outgoing QC with 100% testing. See our Quality Control page for details.
How do I request a quote or sample?
You can request a quote through our Contact page, by clicking the 'Request Quote' button on any product page, or by contacting us via WhatsApp (+86-755-8888-6666) or email (sales@powerconnect-tech.com). We respond to all inquiries within 24 hours.
Need Custom Busbar Fabrication?
Tell us your specifications and our team will provide a tailored proposal.