Battery Energy Storage Systems (BESS) are at the forefront of the energy transition, enabling grid stability, renewable integration, and load balancing. At the heart of these high-current systems lie the conductors—and E91E aluminum busbars from Xinyi offer the ideal combination of electrical performance, weight efficiency, and customization for modern BESS applications.

Why Busbar Selection Matters in BESS

Each module in a BESS contains thousands of cells grouped into battery packs, which must be safely and efficiently interconnected. Busbars play a critical role in conducting high currents between battery packs, inverter units, and protection circuits. Poor conductor choice can lead to overheating, energy loss, and mechanical failure.

E91E Aluminum: Engineered for Energy Storage

Compared to copper, E91E aluminum provides a much lighter alternative with excellent conductivity—making it easier to manage within space-constrained battery racks. Key benefits of using E91E busbars in BESS include:

• ≥ 61.5% IACS conductivity for reliable energy transfer
• Lightweight structure to reduce overall cabinet weight
• Good formability for complex layouts and module integration
• Lower cost per amp than copper-based systems

Custom Fabrication for Modular Systems

Xinyi provides tailored busbar solutions for battery systems of all scales. Whether your BESS design follows a centralized or modular architecture, we can deliver E91E busbars with:

• Custom widths and thicknesses to match cabinet space
• Precision punching and notching for connector alignment
• Bent or flexible configurations for tight installations
• Surface insulation coatings for safe multi-layer routing

Thermal and Electrical Efficiency

E91E aluminum conducts large currents efficiently with less resistive loss than many conventional alloys. This improves the system’s round-trip efficiency while reducing the thermal burden on busbar enclosures—allowing more compact designs and less auxiliary cooling equipment.

Real-World Use Cases

Xinyi’s E91E busbars are already powering projects across utility-scale storage farms, commercial rooftop solar systems, and microgrids. Our solutions support lithium-ion, LFP, and hybrid chemistries, with proven performance in both indoor and outdoor BESS installations.

Partner with Xinyi for Smarter Busbar Design

With years of experience in power conductor manufacturing, Xinyi helps BESS developers optimize busbar layout, materials, and cost-performance balance. We offer rapid prototyping and mass production capabilities for OEMs and integrators worldwide.

Request a Proposal for Your BESS Project

Interested in upgrading to lightweight, high-conductivity busbars? Contact Xinyi to discuss your BESS application and get expert guidance on E91E aluminum busbar sizing, processing, and delivery.