Formed busbars connected high-current circuits within an electric-vehicle battery pack.
The customer’s challenge
High contact resistance caused heating, insulation damage risked short circuits and joints loosened during vibration.
Material and fabrication route
1.0–2.0 mm T2 copper; tin plating; PET insulation.
Process route: Stamping → bending → tin plating → insulation covering → resistance testing → dielectric testing.
Manufacturing changes
Revised conductor sections, controlled insulation coverage, secured joints and a laminated arrangement addressed electrical and packaging requirements.
Engineering analysis
The busbar changes linked conductor geometry, joint security and insulation coverage. A low resistance result alone would not establish acceptable dielectric performance or vibration retention. The recorded electrical tests therefore answer separate questions about the configured assembly. The packaging reduction is a comparison with the earlier arrangement, not an additional electrical rating of the formed copper parts.
Inspection and project results
The assembly reached the reported contact-resistance and dielectric-test values, remained secure during vibration and used 40% less packaging space in the project comparison.
| Project measurement or production detail | Recorded value |
|---|---|
| Contact resistance | ≤0.1 mΩ |
| AC dielectric test | ≥3,000 V |
| Current | ≥200 A |
| Temperature rise | ≤30 K |
These figures describe the project configuration and production scope above. Dimensional, material and production details are identified separately from performance tests. For a new order, the inspection method and acceptance criteria should be agreed against the released drawings.
Planning a similar OEM component
A useful RFQ for this application should make the following interfaces and acceptance requirements clear:
- Current path and connection geometry.
- Insulation coverage and clearances.
- Joint retention under vibration.
- Resistance and dielectric test requirements.
Include the current drawing revision, mating-component information, quantities and required delivery sequence. Identifying unresolved requirements at quotation stage helps distinguish fabrication work from the equipment-level checks that the project needs.
For related manufacturing support, review our Busbar and sheet metal quality capabilities. Use the existing quotation form below to share the drawing package for review.
