Battery Connections
Automotive applications require efficient, reliable connections between the battery cells, battery modules and high-current electrical equipment.
Tranect manufactures bespoke copper components for applications including:
- Battery cell-to-cell and module connections
- Battery pack busbars
- Inverter and power electronics connections
- Motor and drive connections
- High-current DC distribution
- Charging system connections
- Earthing and electrical bonding
Depending on the electrical and mechanical requirements, connections can be manufactured from solid copper, laminated copper strip or flexible copper braid.
Intercell connections
EV battery cells and modules can experience movement caused by vibration, manufacturing tolerances and thermal expansion. A rigid electrical connection can transfer these forces directly into the battery terminals.
Flexible or semi-flexible copper interconnects can accommodate this movement while maintaining a low-resistance electrical connection.
Tranect manufactures laminated copper cell links and flexible copper braided links with dimensions, hole patterns and termination arrangements designed around the battery or module.
Options include:
- Plain, tin-plated or nickel-plated copper
- Custom hole patterns
- Flexible laminated construction
- Braided copper construction
- Insulation where required
- Prototype and production quantities
Solid copper busbars
Solid copper busbars provide a compact, low-resistance method of distributing high currents between batteries, power electronics and other vehicle systems.
Tranect manufactures bespoke copper busbars from customer drawings or can provide design support based on the required current rating and installation envelope.
Our manufacturing capabilities include cutting, profiling, CNC machining, punching, bending, twisting, inserting and assembly, allowing complex three-dimensional connections to be manufactured to suit restricted installation spaces.
Surface finishes including tin, silver and nickel plating can also be specified according to the application.
Flexible busbars
Where vibration, movement or alignment tolerance makes a rigid connection unsuitable, Tranect can manufacture flexible connections using laminated copper strip or copper braid.
Flexible connections can help:
- Isolate vibration from electrical terminals
- Accommodate thermal expansion
- Compensate for manufacturing and assembly tolerances
- Reduce mechanical stress on terminals
- Simplify installation in confined spaces
The geometry, copper cross-sectional area, contact surfaces and mounting holes can all be designed around the application.
Our goal is to offer broad capabilities, competitive pricing, exceptional quality and outstanding service to each and every customer.
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