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Application · Electric Vehicles

EV & Hybrid Busbar Solutions

Electric vehicle battery packs run at 400–800 V and hundreds of amps. Laminated busbars keep those connections compact, low-inductance and reliable.

Where They Are Used

In the Electric Vehicles

The four places busbars carry current in this application.

Module Interconnections

Multi-terminal laminates joining cell groups in parallel and series.

BMS Sense Taps

Paired stud terminals giving consistent measurement points for cell monitoring.

Pack-Level Joints

High-current links to the contactor box and power distribution unit.

Cell-Level Links & Fused Sections

Thin laminates with integrated fuse elements for cell balancing paths.

Design Priorities

Why laminated wins here

  • Compact — Multi-layer construction packs parallel paths into one thin assembly.
  • Low inductance — Conductor spacing and layer orientation keep loops tight.
  • Insulated and sealed — Full edge sealing for high-voltage creepage requirements.
  • Repeatable — Tooled terminals, identical every time, no assembly variation.
Laminated busbars inside an EV battery pack
Engineering Notes

Tell us these at quotation

Voltage class

Dielectric selection follows your platform voltage class — tell us 400 V or 800 V at quotation.

Current profile

Conductor cross-section is sized against continuous and peak current, not nameplate current alone.

Terminal geometry

Terminals are matched to your module studs, contactors and mating buswork.

DFM review

Thermal cycling and vibration profiles are reviewed before tooling.

13+Years since 2012
1–6+Conductor layers
~1000 ACurrent rating
1 dayTechnical response
Project Flow

How a custom project runs

From spec review to shipped, tested parts — one accountable supplier.

Spec ReviewDrawing, current rating, layers and terminals confirmed with you
DFM ReviewEdge distances, weld zones and clearances checked before tooling
QuotationTechnical and commercial quote within one business day
Sample BuildPrototypes for fit and electrical verification
Tooled ProductionControlled process with documented QC per lot
DeliveryPacked to your requirements, test records on request

One technology, every application.

Voltage class, current profile and terminal types — we will share reference configurations and DFM guidance.

FAQ

Frequently asked questions

Straight answers from the engineering team.

What are the standard conductor and dielectric options?
Conductors are C11000 copper as standard, with aluminum available on request, tin plated. Dielectrics include PET, Nomex and epoxy (DLF) films, selected according to your voltage class and operating temperature.
What testing is performed on production lots?
Testing follows the specification agreed at design freeze: dielectric withstand (hipot), insulation resistance, dimensional inspection, visual inspection of plating and edge sealing, and continuity checks per conductor path.
What current ratings can SHANYUAN busbars handle?
Rating is designed per application up to roughly 1000 A, sized against continuous and peak current with thermal margin — see our ampacity chart for the starting reference points.
How long does a sample build take?
A sample is typically produced within 5–7 working days from drawing approval. Fit and electrical verification is done in-house, and you receive test results together with the sample.
What quality system do you follow?
Production follows a documented process chain with batch records: incoming material checks, dimensional inspection, hipot and insulation testing, continuity checks and final visual inspection. Test records are issued per lot on request.
Do you support international shipping and packaging?
Yes. Parts are packed with edge protection, anti-static film and export-grade cartons to your handling requirements, and shipped by sea or air. Commercial documents (invoice, packing list, test records) are provided with every shipment.

EV & Hybrid Busbar Solutions

Send the application, voltage class and current profile — we will share reference configurations and DFM guidance.

Talk to our engineering team

Send drawings, current ratings and voltage class — DFM feedback and a quotation within one business day.

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