Different Types of Aluminum Grade Busbars Used in Prismatic Cells Nowadays

The prismatic cells lithium-ion battery are interconnected by aluminum busbars which are, in addition to being lightweight, great conductors of electricity, and cost-effective. The decision to use aluminum busbars instead of copper ones has been primarily due to their lower cost and easier manufacturing process.

World’s leading battery producers like Highstar, EVE, Ganfeng, Highpower, Great Power, BAK Laser Cell, Gotion High-tech (GHT), High Star, CATL, BYD, CALB, REPT Battero, Lishen Battery, SVOLT Energy, DMEGC, CBAK, Winston battery, Sinopoly battery, A-Grade, LG energy solution, Samsung SDI, Panasonic, among others, have been increasingly using laser-welded aluminum busbars for prismatic cell assemblies as the global demand for efficient, lightweight, and sustainable battery systems continues to rise. This shift reflects the industry’s move toward higher energy density, improved thermal performance, and enhanced manufacturing precision in modern lithium battery packs.

This blog highlights the different grades of aluminum used in prismatic cells busbars : AL1050, AL1060, AL1200, and Commercial Grade aluminum busbars, describing their characteristics, advantages, and the increasing significance they have in the electronics industry and the batteries of electric vehicles.

What Are Prismatic Cells and What Are the Advantages of Using Aluminium Busbars?

The configuration of prismatic cells is such that they come in rectangular or box shapes, utilizing the space with highest energy density. Some of their predominant areas of application are:

• Electric vehicles
• Energy storage systems (ESS)
• Industrial battery packs
• Solar and power backup units

Again and again, these cells are joined through busbars. The conventional copper busbars have been substituted with aluminum ones, which are lighter and less expensive but have a small drop in electrical performance.

Aluminum busbars take advantage of the following in prismatic cells:

• Reduction of copper weight by up to 40%
• Inexpensive materials: lower overall cost of the battery pack.
• Excellent conduction of electricity and heat
• Suitable for laser welding and automated assembly
• If properly plated or sleeved, they become resistant to corrosion.

1. Aluminum Busbar AL1050 Grade

The aluminum busbar AL1050 is at the top of purity in aluminum due to the fact that it contains 99.5% of aluminum. Among the many advantages are:

• Very good electrical conductivity (nearly 60% IACS)
• Excellent corrosion resistance
• Workable and weldable without difficulty

Thus, AL1050 busbars are ideal for the connections of laser-welded prismatic cells i.e Highstar, EVE, Ganfeng, Highpower, Great Power, BAK Laser Cell, Gotion High-tech (GHT), High Star, CATL, BYD, CALB, REPT Battero, Lishen Battery, SVOLT Energy, DMEGC, CBAK, Winston battery, Sinopoly battery, A-Grade, LG energy solution, Samsung SDI, Panasonic because they guarantee both low resistance and strong bonding during assembly.

Some applications of this material include:

• Built into various battery module brands: CATL, EVE, BYD.
• Connectors for laser welding and flexible busbar assemblies

Because AL1050 is soft and very ductile, it finds application in the manufacture of products where close tolerances and high conductivities are the requirements.

2. Aluminum Busbar AL1060 Grade

The AL1060 alloy primarily has 99.6% aluminum within its combination thus, it is regarded as more pure than AL1050.

The reasons why AL1060 is famous can be lined up as:

• Electrical conductivity of the highest quality (~61% IACS)
• High thermal transfer rate
• Best surface for welding lasers
• Moderate resistance to corrosion and oxidation

Among the manufacturers that are using this alloy are Gotion High-Tech, REPT Battero, and Great Power, who are using AL1060 busbars for EV battery packs and storage systems that are very important for performance and weight reduction.

The laser-welded AL1060 busbars contribute to clean and precise connections, thus preventing overheating and voltage drops across the connection.

3. AL1200-grade aluminum busbar

AL1200 is identified as a new pure metal alloy with over 99% aluminum and a slight addition of elements to enhance the durability.

Main features:

• Extraordinary conductivity and ductility
• Custom busbar production with excellent formability
• Laser welding and ultrasonic bonding are very much advised
• Mechanical properties are slightly higher than AL1050/1060

Where used:

• This material has been widely used by CALB, Highstar, Ganfeng, and Highpower to manufacture battery interconnections
• It is mainly located in electric vehicle (EV) modules and energy storage systems
• Application of AL1200 busbar provides a compromise between the cost and performance and thus becomes the option in large-scale battery production lines.

4. Commercial-Grade Aluminum Busbar

Commercial-grade aluminum busbars are the alloys that have been cost-optimized and that show a combination of good conductivity and mechanical strength where ultra-high purity is not the case. Depending on the design requirements, these can be the different types of AL1100, AL3003, or AL6101.

Reasons for the commercialization of these grades:

• More economical than the pure grades
• Fair electrical performance for medium-power applications
• Laser welding and mechanical fastening are both suitable
• Notably tough and malleable for complex battery layouts

Large-scale manufacturers such as Lishen Battery, DMEGC, Sinopoly Battery, and CBAK, among others, are using commercial-grade aluminum busbars in selective areas of the modules where material cost is minimized without compromising the reliability of the product.

The Role of Laser-Welded Aluminum Busbars

One of the major advances in the technology of prismatic cells is laser-welded aluminum busbars.

Why Laser Welding Is Revolutionizing Battery Assembly

• Joints that are perfectly matched, neat and clean with nearly zero heat distortion
• Contact resistance significantly lowered
• High degree of automation in production: the speed and consistency of production can be improved
• No more use of connectors or soldering.

Electric vehicle’s resistance to vibration applications is enhanced

The laser welding method enables not only the joining of ultra-thin and light busbars made of AL1050, AL1060, and AL1200 but also the powering of the module with a constant flow of current.

The companies that have the largest share of the market for prismatic cell lithium battery production are:

Highstar, EVE, Ganfeng, Highpower, Great Power, BAK Laser Cell, Gotion High-tech (GHT), High Star, CATL, BYD, CALB, REPT Battero, Lishen Battery, SVOLT Energy, DMEGC, CBAK, Winston battery, Sinopoly battery, A-Grade, LG energy solution, Samsung SDI, Panasonic.

These companies are working with laser-weldable aluminum alloys busbar so that in the end, besides high durability and performance, they will also have good production as by-products.

Occasionally Used Other Grades of Aluminum

The predominant grades AL1050, AL1060, AL1200, and Commercial Grade are used, but there are other grades that go into specialized applications as well:

• AL1070-which is a higher purity grade and thus used for low resistance interconnects
• AL1350-a grade that is used in power distribution and bus duct systems mainly
• AL6101/AL6061-these are heat treatable alloys that offer extra mechanical strength and are thus used when needed

The factors of cost, conductivity, and weldability have ensured that AL1050-AL1200 remain the most common grades in the production of modern prismatic cells busbars.

Cost and Efficiency Benefits of Aluminum Busbars

Switching from copper to aluminum busbars offers a number of advantages to battery pack manufacturers:

On the whole, using aluminum busbars in the battery module leads to a decrease in the total cost by around 15 to 20% and also an increase in energy density and assembly efficiency.

This is the key factor that has led nearly all major prismatic cell manufacturers such as Highstar, CATL, BYD, CALB, EVE, Ganfeng, Great Power, Winston Battery, and LG Energy Solution to opt for the application of standardized aluminum busbars in the manufacture of their batteries.

Team Up with Adinath Enterprises: Busbar Manufacturer You Can Trust

When you need first-rate aluminum busbars for electric vehicles, energy storage systems or prismatic cells, only then Adinath Enterprises is your trustworthy partner.

We are the busbar provider and manufacturer of the following:

• AL1050 / AL1060 / AL1200 / Commercial Grade aluminum busbars
• Busbar solutions for laser welding
• Custom fabricated and sleeved busbars for prismatic cell and switchgear
• OEM & ODM busbar design based on your specifications

 By means of exact manufacturing, stringent quality checks, and effective production, Adinath Enterprises guarantees that all applications will have the best electrical performance and life span. Right now, connect with Adinath Enterprises to explore the possibilities of your aluminum busbars and improve the connections of your prismatic cell with dependable quality.

Final Thoughts

The everlasting dependency on EVs (electric vehicles) and energy storage systems has caused the market to grow and thus, the demand for efficient, lightweight, and cheap busbars has become the strongest. AL1050, AL1060, AL1200, and Commercial Grade aluminum busbars remain the most advanced materials especially with laser-weld technology that guarantees accuracy, trustworthiness, and scalability. The whole prismatic cell market from CATL to BYD, from EVE to Gotion High-Tech is gradually shifting to laser-welded aluminum busbars: the more intelligent choice for the future battery connectivity.