The main differences between new energy copper and aluminum busbar connectors are in terms of conductivity, mechanical properties, cost, and weight. ‌

conductivity

Copper bar: Copper has excellent conductivity, second only to silver, with high conductivity and good conductivity stability. Copper bars are suitable for situations that require high current transmission, ensuring stable transmission of electrical energy.

Aluminum busbar: Although aluminum has good electrical conductivity, second only to copper, its electrical resistivity is higher and its conductivity is slightly inferior to copper busbar at the same cross-sectional area.

Mechanical properties

Copper bar: Copper has high hardness and tensile strength, making it suitable for withstanding large mechanical stresses. Copper bars are not easily deformed during use and have good stability.

Aluminum busbar: Aluminum is a soft material with low tensile strength, which is prone to creep and relaxation. Long term use may lead to poor contact and heat generation.

Cost and weight

Copper bars: Copper is expensive, dense, and heavy, which makes the cost of copper bars relatively high.

Aluminum busbar: Aluminum has low density, light weight, and low cost, making it suitable for applications that require lightweighting.

Application scenarios

Copper busbar: Due to its high conductivity and stability, copper is commonly used in applications that require extremely high current transmission, such as high-voltage power transmission and electrical systems that require high reliability.

Aluminum busbar: Due to its lightweight and low-cost characteristics, aluminum busbar is commonly used in situations with strict weight requirements, such as the connection of new energy vehicle battery packs.