The rapid growth of the electric vehicle (EV) market demands innovative solutions for power distribution within battery systems. Traditional copper busbars are increasingly being replaced by lightweight, cost-effective alternatives. Among them, E91E aluminum busbar supplied by Xinyi has emerged as a high-performance choice, tailored to the specific needs of EV platforms and battery packs.

Lightweight Design for Vehicle Efficiency

Weight reduction is critical in EV engineering. E91E aluminum busbars weigh only one-third of copper busbars while maintaining excellent electrical conductivity (≥61.5% IACS). Using E91E helps manufacturers reduce the overall weight of the battery pack and improve vehicle range and energy efficiency.

Excellent Thermal Conductivity

Battery packs generate substantial heat during charge and discharge cycles. E91E aluminum offers superior thermal conductivity, helping dissipate heat more effectively than traditional copper systems in certain configurations. This reduces thermal stress on battery cells and prolongs system lifespan.

Flexibility for Customized Battery Layouts

Modern EV battery designs often involve compact, modular, and layered assemblies. E91E aluminum busbars from Xinyi can be easily formed, punched, and laser-cut to fit these geometries. Whether it’s cell-to-cell, module-to-module, or pack-to-inverter connections, E91E provides the dimensional flexibility needed without sacrificing performance.

Surface Treatments for Enhanced Contact and Durability

To ensure optimal contact resistance and corrosion protection, Xinyi offers surface treatment options for E91E busbars, including tin plating, nickel coating, and insulation films. These enhancements make aluminum busbars more robust under the humidity and vibration typical of EV environments.

Superior Cost-to-Performance Ratio

E91E aluminum busbars are not only lighter and easier to process than copper but also significantly cheaper—reducing BOM (bill of materials) costs for high-volume battery systems. This makes them particularly attractive to EV startups and global OEMs seeking scalability.

Trusted by Tier-One EV Suppliers

Xinyi has supplied E91E aluminum busbars to several leading electric vehicle manufacturers and battery integrators. Our strict quality control ensures consistent mechanical and electrical properties across every delivery, meeting international automotive standards such as IATF 16949.

As the EV industry accelerates, materials like E91E aluminum busbar are transforming how energy is distributed inside vehicles. Xinyi’s advanced aluminum solutions offer the perfect balance of weight, conductivity, safety, and manufacturability—making them a smart choice for next-generation electric mobility.

Work with Xinyi

Whether you're developing a new battery system or optimizing an existing design, contact Xinyi to explore our E91E busbar solutions for EVs. We offer material customization, technical consulting, and supply chain support tailored to the fast-paced automotive sector.