Customized Flexible Copper Busbars for an Energy Storage System

Application: Battery Energy Storage Systems

Customer: An energy storage system integrator (name withheld)

Products: Flexible Laminated Copper Busbars

Project Background

An energy storage system integrator required customized high-current connections for battery modules installed within a compact cabinet layout. The connections needed to accommodate vibration, thermal expansion and minor assembly deviations while maintaining a stable electrical connection.

Customer Requirements

The customer needed flexible busbars with project-specific dimensions, terminal-hole positions and insulation coverage. The exposed contact areas also had to match the terminals inside the battery cabinet.

Avantar Solution

Based on the customer’s drawings and current-carrying requirements, Avantar supported the manufacture of flexible laminated copper busbars using stacked high-purity copper foils.

The busbars were prepared with welded terminal ends, customized mounting holes and partial insulation, leaving only the required electrical contact areas exposed. Dimensions and connection details were reviewed before production.

Project Support

The drawing-based approach allowed the busbars to be adapted to the available cabinet space and connection layout. Sample evaluation could also be arranged before batch production to verify dimensions, flexibility and installation compatibility.

Related Products: Flexible Laminated Copper Busbar, Flexible Copper Braid Connectors, Copper Busbar Links and Connectors