Flexible Busbars for EV Battery Packs (400/800 V)

Why Flexible Busbars in EV Battery Packs?

Battery modules in a vehicle move relative to one another. Road vibration, thermal cycling and cell swelling over the life of the pack cause constant relative movement. A rigid busbar transmits these forces directly to the cell terminals, the most sensitive point in the pack. Flexible busbars absorb the movement and protect terminals and welded joints throughout the vehicle's service life.

For the same current-carrying capacity, the flat profile of the laminated construction takes up less space than a round cable, an advantage in densely packed battery systems. The flat design also dissipates heat better, has lower inductance and simplifies automated assembly compared with cable routing.

Nickel-plated copper busbars are the standard solution for connecting to aluminium cell terminals. The nickel layer prevents galvanic corrosion at the copper–aluminium interface and is compatible with laser and ultrasonic welding. Tin plating is used for bolted aluminium connections.

Applications by Cell Format

Prismatic cells
Flexible connections between prismatic cells in module configurations.
Pouch cells
Low-profile busbars for connecting pouch cell tabs in series and parallel.
Cylindrical cells
Connectors for modules with 18650, 21700 and 4680 cells.
Module-to-module
High-current connections between battery modules within the pack.

Applications

Connections between battery modules
Pack main busbars
Inverter and motor controller connections
DC fast-charging circuits
High-voltage junction boxes
On-board charger connections

Technical Data

Parameter	Specification
Rated current	100 A – 2,000 A (continuous)
Voltage	For 400 V and 800 V systems (up to 1,000 V DC)
Conductor material	High-conductivity copper (purity ≥ 99.9%), e.g. Cu-ETP, Cu-HCP or Cu-OF (OFC), as required
Lamination thickness	0.1 – 0.2 mm (typical)
Surface	Nickel-plated (for connections to aluminium) or tin-plated
Insulation	Optional, e.g. polyimide (Kapton®), PET or aramid (Nomex®)
Operating temperature	Depends on insulation material

Flexible Busbars for Your Battery Project

Send us your drawing or your requirements for current, voltage and installation space. We manufacture flexible busbars for manufacturers of battery systems, vehicles and charging equipment worldwide.

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