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Aluminium connectors for high voltage and cell systems
In order to ensure reliable energy transmission in modern electric vehicles and energy storage systems, aluminium connectors are indispensable. They guarantee safe and efficient current flow between battery cells, modules, control units, and power electronics, thereby maximizing the overall performance of the system. At Speira, we manufacture and supply flat-rolled aluminium for busbars and connectors that meet the highest quality standards.
High performance for every contact with aluminium
With our aluminium solutions for cell contacting systems, high-voltage connectors, and busbars, we strike a balance between high conductivity, lightweight potential, and strength. Depending on the application, we offer specific material solutions whose properties are precisely tailored to the respective requirements. This makes it possible, for example, to achieve a perfect balance between electrical conductivity and strength.
Advantages of the pre-material for aluminium busbars and connectors at a glance:
- Excellent conductivity for low-loss energy transmission
- Low material density that reduces vehicle weight
- Corrosion resistance for long-lasting connections
- High strength for secure mechanical joining techniques
- Easy further processing for efficient and customized customer processes
- Environmentally friendly, thanks to infinite recyclability
Contact us Aluminium for busbars and connectors
Our dedicated team is happy to assist you. We take the time for you and your project so that we can get started together as partners. Do you have specific questions about our aluminium solutions for busbar and connectors? We’ll be glad to provide you with personalized advice. Just contact us via our contact form.
Aluminium for battery busbars and connectors
For the next stages of development in e-mobility, it is crucial that battery systems continuously achieve higher voltages. This improves driving range, charging speed, and efficiency. Robust copper or aluminium cell contacting systems, including aluminium battery busbars and connectors, are also used to create reliable connections, remain durable under extreme conditions, and save both space and weight.
In electric vehicles, aluminium is used for electrical connections at various levels of the battery: individual battery cells are connected in series or parallel to achieve the system voltage and required current. Contacting systems for batteries, such as battery terminal connectors made of aluminium, ensure short, efficient conduction paths between the individual cells within the battery modules. At the module level, battery busbars connect the individual modules into a powerful high-voltage system that ensures consistent system performance.
Advantages of aluminium as pre-material for busbars and connectors
When it comes to contacting systems, many people first think of copper. Indeed, this material has a well-established role in this field and offers many benefits. However, aluminium has proven to be a strong alternative for connectors, with its own distinct advantages.
Light weight
With a density of about 2.7 g/cm³, aluminium offers an exceptionally low weight – for comparison: that’s less than one third of copper. This property can significantly reduce the overall weight of the HV system in drive batteries, which offers a crucial competitive advantage in the automotive and the aerospace industries.
Cost advantage
The price per ton of aluminium is less than one third of the price of copper. Due to the lower density of aluminium compared to copper, this cost advantage is further enhanced, making aluminium an extremely cost-efficient alternative for connectors.
Availability
Recent analyses predict that the energy transition and the growth of electromobility will lead to an increased demand for copper, while the global supply will not be sufficient to meet this demand. Tailor-made aluminium solutions can help bridge part of this supply gap and sustainably support the energy transition.
Our material solutions for your application: ION Connect
Aluminium alloys of the 1000 series are characterized primarily by their high purity. It is the preferred material for cell contacting systems when high electrical conductivity and laser weldability are required.
The ION Connect 1 Series includes alloys such as 1050, 1060, and 1070 in various hardness levels and surface conditions.
The high electrical conductivity required by cell contacting and HV systems is usually achieved through technically pure alloys made from primary metal.
With ION Connect 3, we provide a solution that not only requires only a small amount of primary metal but also increases thermal resistance and thus the temperature limits. This paves the way for more sustainable connectors based on aluminium.
Through targeted process control during manufacturing, alloys of the 6000 series can achieve high mechanical strength. With precise control of the chemical composition of these materials, the balance between strength and electrical conductivity can be specifically adjusted. This property becomes particularly valuable when busbars in the battery system need to be bolted or otherwise mechanically fixed.
Our aluminium alloys ION Connect 6-BS and 6-BC were developed precisely for this purpose and offer a customized balance of mechanical strength and electrical conductivity.
Aluminium from Speira for busbars and connectors
Aluminium is an essential part of the energy and mobility transition. With our comprehensive alloy portfolio, we offer application-specific material solutions for your battery system – from the battery cell to the pack. Especially in the area of aluminium connectors and aluminium busbars, the physical properties of aluminium – such as its low density, high electrical conductivity, and good formability – can be purposefully utilized and optimized for specific requirements. With our expertise and years of experience, we are your partner for the energy supply and mobility of tomorrow.
Get in touch now: let’s discuss your project
We are happy to provide a personal consultation and support your decision to use aluminium from Speira for your busbars and cell connectors. Feel free to reach out to us via the contact form. We look forward to hearing from you!
