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Flexible Copper Braided Wires

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BRIDGOLD Copper-Aluminum Composite Rigid Busbars
BRIDGOLD Copper-Aluminum Composite Rigid Busbars
BRIDGOLD Copper-Aluminum Composite Rigid Busbars
BRIDGOLD Copper-Aluminum Composite Rigid Busbars
BRIDGOLD Copper-Aluminum Composite Rigid Busbars
BRIDGOLD Copper-Aluminum Composite Rigid Busbars

China Suppliers Copper-Aluminum Composite Rigid Busbars Factory - Lightweight, Cost-Effective, High Conductivity Solutions

The copper-aluminum composite rigid busbar from our factory is engineered with an aluminum core and a metallurgically bonded copper cladding. This innovative design merges the high conductivity of copper with the lightweight and cost advantages of aluminum. Offering a conductivity of 69.5% IACS and a current-carrying capacity of 85% to 86% compared to solid copper busbars, our product stands out in performance. With a density that is only 37% to 40% of pure copper, you can achieve a weight reduction of approximately 55% at the same volume, leading to remarkable overall cost savings of about 35%. The strong interfacial bond allows for versatility in applications such as bending, punching, and shearing. Operating efficiently in temperatures ranging from -40℃ to +105℃, this busbar is widely used in distribution cabinets, busway systems, EV battery packs, and energy storage solutions. As leading suppliers in China, we also provide custom sizes tailored to your specifications.
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    Product Details

    Product Advantages

    Bimetallic Structure

    Aluminum core with copper cladding (copper volume ratio ~20%) via metallurgical bonding, offering copper’s conductivity and oxidation resistance combined with aluminum’s low weight and cost.

    Key Electrical Performance

    Conductivity 69.5% IACS, current-carrying capacity 85%~86% of equivalent copper busbar; surface tin-plating available for enhanced anti-oxidation.

    Lightweight & Cost-Effective

    Density 37%~40% of pure copper, weight reduction ~55% at same volume, material cost savings ~35%, and 2+ times length per unit weight compared to copper.

    Reliable Workability

    High bond strength allows 90° bending, punching, shearing without delamination; stable transition layer minimizes galvanic corrosion.

    Product Display

    Copper-Aluminum Composite Rigid Busbars (1)
    Copper-Aluminum Composite Rigid Busbars (2)
    Copper-Aluminum Composite Rigid Busbars (3)

    Operating Conditions

    Temperature: -40℃~+105℃ (long-term), short-term up to 150℃; voltage 1kV~35kV, current 250A~5000A.

    Applications: LV/MV distribution, busway, EV battery busbars, PV inverters, energy storage – ideal replacement for pure copper/aluminum.

    Maintenance

    Inspect torque and surface oxidation regularly; clean with dry cloth, avoid acids/alkalis.

    Designed life: ≥25 years.

    After-Sales Service

    Free technical support: engineering consultation, drawings...

    Custom orders: lead time & quality report provided before shipment

    Contact Us

    Zhejiang Bridgold Copper Tech Co.,Ltd. is a professional leader China copper braided shunt, copper braided ground strap, copper braided connector, Copper Braided Busbar, rigid copper (aluminum) busbars, extruded copper(aluminum) busbars, copper-aluminum composite rigid busbars manufacturers and suppliers with high quality and low price. Welcome to contact us.

    Frequently Asked Questions (FAQ)

    What are the primary cost and weight benefits of copper-aluminum composite rigid busbars?

    They reduce material weight by roughly 55% and cut costs by up to 35% compared to solid copper bars, while providing over twice the linear length per unit of weight.

    Will delamination occur during bending or machining?

    No. Thanks to metallurgical bonding, the bimetallic interface provides superior bond strength that supports 90° bending, cutting, and hole punching without layer separation.

    How is galvanic corrosion prevented between copper and aluminum?

    A specialized atomic-level transition layer created during metallurgical bonding isolates environmental air and moisture, effectively mitigating electrochemical and galvanic corrosion risks.

    What is the expected operating lifespan and working temperature?

    The designed operating life is ≥25 years under continuous temperatures ranging from -40℃ to +105℃, with short-term thermal withstand ratings reaching up to 150℃.

    Can surface treatment like tin plating be applied?

    Yes. Surface tin plating is available upon request to enhance anti-oxidation performance, reduce contact resistance, and ensure durability in harsh industrial environments.

    Do you offer custom fabrication and engineering drawings?

    Yes. We provide complete engineering consultation, 2D/3D design support, and custom processing according to client specifications, accompanied by full quality test reports prior to delivery.