Battery Busbar Manufacturing Process and Quality Standards
Introduction
How are battery busbars made, and what ensures their safety and performance?
This article provides a clear, step-by-step overview of the battery busbar manufacturing process—from raw copper sheet selection to plating, inspection, and certification. Each stage is designed to meet strict international quality standards such as ISO 9001, UL 1973, and EU Battery Regulation 2023/1542.
Wellgo Battery, a leading battery busbar manufacturer, ensures that every custom copper-nickel busbar meets the highest standards of conductivity, durability, and consistency.
Raw Material Selection: Copper, Nickel, and Aluminum
The process begins with selecting premium materials. Copper busbars remain the industry standard due to their high conductivity (up to 59 MS/m) and superior heat dissipation. For lightweight or hybrid applications, nickel or aluminum busbars may also be used.
|
Material |
Conductivity |
Thermal Conductivity |
Typical Use |
|
Copper (C11000) |
★★★★★ |
401 W/m·K |
EV, ESS |
|
Nickel |
★★★☆☆ |
91 W/m·K |
Spot welding connectors |
|
Aluminum |
★★★★☆ |
237 W/m·K |
Lightweight designs |
Wellgo Battery sources oxygen-free copper (C10200) directly from verified LME suppliers, guaranteeing low impurity levels and stable performance in high-current lithium-ion battery busbars (LME).
Cutting and Stamping: Precision Shaping
After material selection, copper sheets are cut and stamped into required geometries. Advanced CNC and progressive stamping machines ensure precise dimensions and smooth edges, preventing burrs that could increase electrical resistance or risk short circuits.
Wellgo Battery uses automated laser-cutting systems with micron-level accuracy, supporting complex battery pack layouts for EVs and energy storage systems.
Source: Journal of Manufacturing Processes | ScienceDirect.com by Elsevier
Surface Treatment: Cleaning and Coating
Surface treatment removes oxidation and contaminants to prepare the busbar surface for plating. The standard sequence includes:
1. Degreasing and ultrasonic cleaning
2. Acid pickling and rinsing
3. Drying under controlled humidity
The goal is to ensure strong adhesion of the nickel or tin plating, which enhances corrosion resistance and solderability.
Wellgo Battery’s plating line supports nickel, tin, and silver coatings, tailored to specific current-carrying or environmental needs.
Plating and Coating: Enhancing Durability
Plating plays a crucial role in battery busbar longevity.
|
Plating Type |
Main Function |
Cost Impact |
Wellgo Battery Application |
|
Nickel Plating |
Corrosion & wear resistance |
+10–15% |
EV connectors |
|
Tin Plating |
Oxidation prevention, solderability |
+5–8% |
ESS modules |
|
Silver Plating |
Ultra-low resistance |
+20–30% |
High-current aerospace |
Wellgo Battery uses electroplating and immersion tin techniques to create consistent coatings that maintain low contact resistance over thousands of cycles.
Welding Preparation: Laser and Ultrasonic Options
Proper busbar welding ensures reliable electrical flow. The two main welding methods are laser welding (for copper or nickel) and ultrasonic welding (for aluminum or thin tabs).
● Laser Welding: Deep penetration and high strength.
● Ultrasonic Welding: Low heat, ideal for thin-layer joints.
Wellgo Battery performs both welding types in-house, ensuring compatibility with EV battery pack standards and minimizing resistance at junction points.
Insulation and Assembly
Once welded, insulation layers or heat-shrink tubing are applied to prevent electrical leakage or arcing.
Every battery busbar assembly is tested for dielectric strength and insulation resistance, ensuring compliance with IEC 60664-1 standards.
Wellgo Battery uses flame-retardant insulation materials rated for UL94-V0, ensuring both safety and mechanical integrity in harsh environments.
Dimensional and Electrical Testing
Precision inspection is essential to verify busbar geometry, thickness, and resistance.
● Tests include:3D laser measurement for dimensional accuracy
● Micro-ohm resistance testing (<0.2 mΩ tolerance)
● Thermal cycling (-40°C to +125°C)
Every Wellgo Battery busbar undergoes 100% inspection before packaging, supported by traceable QR-coded certification records.
Quality Certification and Compliance
Meeting international compliance standards is a critical part of the busbar manufacturing process.
Wellgo Battery’s production lines are certified under:
● ISO 9001:2015 – Quality Management
● ISO 14001:2018 – Environmental Management
● RoHS & REACH – Chemical safety compliance
● EU Battery Regulation 2023/1542 – Material traceability and recyclability
These certifications guarantee consistent battery busbar quality for global OEM and ESS clients.
Packaging and Logistics
After inspection, busbars are packaged using anti-oxidation wrapping and moisture-proof sealing to prevent surface corrosion.
Wellgo Battery provides global export service, delivering custom-packed busbars to over 30 countries with full material traceability and logistics tracking.
Summary: From Raw Copper to Certified Busbar
|
Stage |
Process |
Key Quality Focus |
|
1 |
Material selection |
Purity & conductivity |
|
2 |
Stamping/Cutting |
Dimensional accuracy |
|
3 |
Cleaning |
Surface adhesion |
|
4 |
Plating |
Corrosion resistance |
|
5 |
Welding |
Joint strength |
|
6 |
Insulation |
Electrical safety |
|
7 |
Testing |
Low resistance & durability |
|
8 |
Certification |
ISO & regulatory compliance |
From design to delivery, Wellgo Battery ensures every battery busbar meets international standards for performance, safety, and sustainability.
