Three Major Breakthroughs in Laminated Busbar Technology Empower NEVs with Cost Reduction and Efficiency Improvement

Recently, driven by the upgrade of new energy vehicle (NEV) high-voltage platforms and green manufacturing, laminated busbar technology has achieved concentrated breakthroughs. AVIC, BYD, and CATL, three leading enterprises, have successively released innovative achievements, realizing iterations in material substitution, structural optimization, and composite material fields, providing core support for the popularization of 800V high-voltage platforms, range improvement, and energy storage upgrades

Aluminum Replaces Copper: Dual Breakthroughs in Cost and Weight Reduction

At the 2025 International Connection Technology Conference, the high-power charging aluminum busbar displayed by AVIC attracted wide attention. The product uses high-purity aluminum conductors instead of traditional copper wires, achieving a 40%-50% weight reduction and 30%-40% cost reduction. Its easy-bending feature adapts to the 800A-1000A high-power charging needs of 800V high-voltage platforms, in line with the national "aluminum replacing copper" strategy. Currently, the technology has been applied to multiple high-end NEV models, with a market penetration rate of 33%.

Low-Inductance Innovation: Synchronous Improvement of Range and Performance

BYD's 8th-generation electric platform adopts laminated busbar technology. Through the electromagnetic field self-canceling structure design, the busbar inductance is reduced to 5nH. Combined with SiC modules, the switching frequency is increased to 100kHz, effectively suppressing IGBT turn-off overvoltage. Test data shows that the vehicle's electrical energy utilization rate is increased by 7.8%, and the driving range is extended by 52km, providing key support for the performance breakthrough of high-voltage platform models.

Composite Material Upgrade: Synergistic Development of Energy Storage and Vehicle Applications

CATL has applied silicon carbide copper-aluminum composite busbars in overseas energy storage projects. Through material optimization, the thermal conductivity is increased by 17% while maintaining 98.2% electrical conductivity, meeting the high-temperature resistance and creep resistance requirements of high-power inverters. The solution reduces the volume of energy storage systems by 37% and increases annual power generation by 2.3%. Its technical concept also provides cross-border reference for the high-voltage power distribution systems of NEVs.