Custom Busbars: Injection Molded Busbars for EV Battery Systems

Injection-molded busbars are made using injection molding technology, combining precision machining with efficient production, and are commonly used in new energy power distribution systems. The process involves injecting molten busbar material into molds under heat and pressure, followed by precise cooling to ensure uniform dimensions and shape. Their design is particularly suited for power connection and distribution in EV battery systems.

  • Material: T2 Copper
  • Edge Type: Customized
  • Plating: Tin plating, Nickle plating
  • Size: Customized

Product Features

  1. High Precision and Complex Shapes: Injection molding enables micron-level precision, allowing the production of copper busbars with complex shapes to meet the non-standard design requirements of specialized equipment. This is particularly important for compact and customized busbar applications in the electrical field.

  2. Efficient Mass Production: The highly automated injection molding process supports large-scale production, significantly reducing production cycles. Compared to traditional methods, it improves efficiency while lowering labor and unit costs.

  3. Superior Surface Quality: Injection-molded busbars feature smooth, flawless surfaces, free of bubbles and defects. This is critical for high-end electrical equipment, enhancing both aesthetics and electrical performance.

  4. High Material Utilization: Injection molding precisely controls material usage, minimizing waste compared to traditional cutting methods. Its flexible design capabilities optimize material distribution, balancing mechanical strength and electrical performance while reducing costs.

Injection Molded Busbars

Application Advantages

The performance of busbars directly impacts the stability and safety of electrical equipment. Injection-molded busbars offer distinct advantages due to their precision, surface quality, and production efficiency:

  1. Stable Electrical Performance: Their smooth, flat surfaces ensure excellent conductivity while reducing energy loss and arcing risks.

  2. Customization Flexibility: The adaptability of injection molding meets diverse design needs, particularly for complex shapes and special dimensions.

  3. Ideal for Modern Applications: In new energy sectors such as EV battery systems, energy storage, and smart grids, injection-molded busbars excel in supporting lightweight and efficient designs, making them a preferred choice for industry advancements.


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