What is a 1050 Aluminum Strip?
A 1050 aluminum strip for battery flexible connection is a commercial high-purity aluminum material containing at least 99.5% pure aluminum. It is specifically produced to make flexible busbars, soft connectors, and conductive links inside lithium-ion battery systems.
Because of its high purity, it offers highly stable electrical conductivity and excellent thermal transfer. In the battery manufacturing industry, this material is processed into an "O temper" (fully annealed state). This makes the metal extremely soft and flexible, allowing it to absorb shocks, vibrations, and thermal expansion inside moving vehicles without breaking or cracking. Today, it is widely used as a lightweight and cost-effective alternative to copper in electric vehicle (EV) battery packs and energy storage systems (ESS).
Why 1050 Aluminum is the Best Choice for Battery Flexible Connectors
When designing a battery pack, engineers look for materials that balance performance with manufacturing costs. Here is why 1050 aluminum is widely selected:
- High Electrical Conductivity: It provides about 60% of the conductivity of the International Annealed Copper Standard (IACS). This is more than enough to handle the high-current demands of modern EV batteries while keeping resistance low.
- Significant Weight Reduction: The density of 1050 aluminum is 2.71 g/cm³. This makes it about 50% lighter than copper. In electric vehicles, reducing the weight of the battery pack directly increases the driving range.
- High Flexibility (Elongation): With an elongation rate of 25% or more, it can be bent, folded, and stamped multiple times without snapping.
Strong Corrosion Resistance: The natural oxide layer on aluminum protects the connectors from rust and degradation over a long service life. - Lower Material Cost: The raw material cost of aluminum is fundamentally lower and more stable than copper, helping battery manufacturers reduce overall production costs.
Aluminum vs Copper Busbar
Choosing between aluminum and copper is a critical buying decision for purchasing managers. Here is a direct comparison to help you decide.
| Material | Electrical Conductivity | Weight | Cost | Flexibility | Recommendation |
| Copper | 100% IACS | Heavy | High | Moderate | Best for high-end, space-limited uses |
| 1050 Aluminum | ~60% IACS | Light | Low | Excellent | Best overall choice for EV mass production |
Conclusion: While copper has better pure conductivity, 1050 aluminum provides the best balance of electrical performance, weight saving, and cost control. To achieve the same conductivity as copper, you simply use a slightly thicker or wider aluminum strip. The end result is still much lighter and cheaper than using copper.
Chemical Composition of 1050 Aluminum Strip
The performance of 1050 aluminum relies entirely on keeping impurity levels low. Even small amounts of other metals can reduce its ability to conduct electricity.
| Element | Content (%) |
| Aluminum (Al) | ≥ 99.50 |
| Silicon (Si) | ≤ 0.25 |
| Iron (Fe) | ≤ 0.40 |
| Copper (Cu) | ≤ 0.05 |
| Manganese (Mn) | ≤ 0.05 |
| Magnesium (Mg) | ≤ 0.05 |
| Zinc (Zn) | ≤ 0.05 |
| Others | ≤ 0.03 |
Mechanical Properties of 1050 Aluminum Strip
For flexible battery connections, the mechanical state of the metal is just as important as the chemistry. We supply this material in the "O Temper" (fully annealed).
| Property | Value |
| Tensile Strength | 60 – 95 MPa |
| Yield Strength | ≥ 20 MPa |
| Elongation | ≥ 25% |
| Hardness | ~ 20 – 25 HB |
The most critical data point here is the Elongation (≥ 25%). This guarantees maximum flexibility. When workers or automated machines bend the strip into complex shapes to fit between battery cells, the metal will yield smoothly instead of forming micro-cracks. Microcracks are dangerous because they increase electrical resistance and generate unwanted heat.
Are you facing issues with aluminum strips cracking during the bending process? Your current supplier might be getting the annealing process wrong. Contact GNEE today for a quick quote and free test samples of our high-elongation 1050-O aluminum strip.
Email us now with your thickness and width requirements.1050 Aluminum Strip Electrical & Thermal Properties
Battery connectors must carry heavy currents and pull heat away from the battery cells.
| Property | Value |
| Electrical Conductivity | ~ 60% IACS |
| Thermal Conductivity | ~ 230 W/m·K |
| Electrical Resistivity | ~ 0.0282 μΩ·m |
| Melting Point | ~ 660°C |
These properties ensure stable current flow. When the battery is charging rapidly, the aluminum strip helps dissipate the generated heat, preventing the battery modules from overheating.
Standard Specifications of 1050 Aluminum Strip
At GNEE, we slit and cut the master aluminum coils into specific dimensions based on your factory's production line requirements.
| Parameter | Standard Range |
| Thickness | 0.05 mm – 3.0 mm |
| Width | 100 mm – 500 mm |
| Temper | O (Annealed) / H14 (Half Hard) |
| Surface Finish | Clean, Degreased, Mill Finish |
| Edge Condition | Slit Edge, Rounded Edge |
| Production Standard | ASTM B209 / EN 573 / GB/T 3880 |
Note: For flexible busbars made of many thin stacked layers, thicknesses of 0.1mm to 0.5mm are the most commonly ordered.
1050 Aluminum Strip Width Tolerances
| Thickness Range | Width ≤ 100mm | 100mm < Width ≤ 300mm | 300mm < Width ≤ 500mm |
| >0.20～0.60 | +0.5 | +0.6 | +1.0 |
| >0.60～1.00 | +0.5 | +0.8 | +1.5 |
| >1.00～2.00 | +0.6 | +1.0 | +2.0 |
| >2.00～3.00 | +2.0 | +2.0 | +2.0 |
| >3.00～5.00 | +3.0 | +3.0 | +3.0 |
| >5.00～8.00 | +7.0 | +7.0 | +7.0 |
How 1050 aluminum Strip Flexible Busbars are Made
Precision Slitting: The aluminum coil is cut into narrow strips. Edge quality is strictly controlled to avoid sharp burrs that could puncture battery insulation.
Surface Degreasing: Rolling oils must be completely removed. We deliver dry, clean strips to ensure your welding process does not fail.
Lamination (Stacking): Multiple layers of thin aluminum foil/strip are stacked together to reach the required current-carrying capacity while remaining highly bendable.
Welding: The ends of the stacked strips are solid-welded together. This is usually done using ultrasonic welding or diffusion welding. Clean aluminum is critical here; any dirt or oil will cause a weak weld.
Insulation: The middle section of the flexible busbar is often wrapped in heat-shrink tubing (like PVC or PE) for electrical safety.
Applications of 1050 aluminum strip
1050 aluminum strip is not for heavy structural support; it is an electrical component. You will find it commonly used in:
- Electric Cars and Scooters: Connecting the hundreds of individual cylindrical or prismatic battery cells inside the vehicle's floor pan.
- Home Energy Storage Walls: Linking battery modules inside solar energy storage units used in residential garages.
- Portable Power Stations: The flexible internal wiring for heavy-duty camping power banks.
- Industrial Forklifts: Connecting the large traction battery packs that power electric warehouse equipment.
- The main function in all these uses is to conduct power safely while absorbing the physical shocks and bumps of daily movement.
Customer Pain Points & Solutions
When buying aluminum strip for battery uses, purchasers often face specific manufacturing challenges. Here is how we solve them:
| Common Pain Point | The GNEE Solution |
| Cracking during installation | We strictly control the annealing furnace temperature to guarantee O-temper with high elongation. |
| Poor welding results | We use a high-pressure hot water and chemical degreasing line. The surface is 100% free of rolling oils. |
| Inconsistent conductivity | We only use A-grade aluminum ingots, ensuring ≥ 99.5% purity. No recycled scrap is mixed in. |
| Sharp edges cutting wires | We offer edge-trimming services to remove sharp slitting burrs. |
Material Comparison: 1050 vs 1060 vs 3003
Buyers often ask which aluminum grade to choose.
| Alloy Grade | Conductivity | Strength | Flexibility | Best Application |
| 1050 | High | Low | Excellent | Flexible connectors, soft busbars |
| 1060 | Slightly Higher | Low | Excellent | Direct alternative to 1050 |
| 3003 | Medium | Higher | Moderate | Battery casings, structural frames |
Use 1050 or 1060 for the parts that carry electricity and need to bend. Use 3003 for the hard outer shell that protects the battery.
Quality Control & Packing
Exporting aluminum strip requires strict quality checks and tough packaging. Sea salt and moisture can corrode aluminum during ocean freight.
- Quality Control: Every batch from GNEE comes with a Material Test Certificate (MTC). We test the chemical composition, tensile strength, elongation, and surface cleanliness. Our factory operates under ISO 9001 standards, and we accept third-party inspections like SGS or BV.
- Export Packing: The strips are wound into coils. We wrap them in neutral anti-scratch paper, seal them tightly in moisture-proof plastic film, and add desiccant bags. They are then strapped securely to strong, fumigation-free wooden pallets. This guarantees the material arrives dry and ready to use.
Pricing Reference (SMM Base)
Aluminum strip pricing is transparent and consists of two parts: Raw Material Ingot Price + Processing Fee.
The raw material price changes daily based on the SMM (Shanghai Metals Market).
The processing fee depends on the thickness and width you need. Thinner strips require more rolling time, so the processing fee is slightly higher.
Estimated Pricing Guide (For Buyer Reference Only):
| Product Specs | Thickness | Estimated Price (USD/Ton) |
| 1050 Aluminum Strip | 0.5 mm – 1.0 mm | $2,400 – $2,800 |
| 1050 Aluminum Strip | 1.0 mm – 3.0 mm | $2,300 – $2,700 |
Please note: The exact price depends on the daily SMM aluminum ingot rate and your total order quantity.
FAQ
Q1: Why is 1050 aluminum used in battery connectors?
Because it offers high electrical conductivity, excellent flexibility for bending, and a lower raw material cost compared to copper.
Q2: Is aluminum better than copper for EV batteries?
For mass-produced electric vehicles, yes. Aluminum is 50% lighter and significantly cheaper than copper, which helps reduce the total cost and weight of the car without losing power efficiency.
Q3: What temper is best for flexible busbars?
The "O" temper (fully annealed) is the best. It makes the metal soft enough to bend sharply and absorb vibrations without cracking.
Q4: Can a 1050 aluminum strip be welded?
Yes. It is highly suitable for ultrasonic welding, diffusion welding, and laser welding, provided the surface is clean and free of oil.
Why Choose GNEE as Your Supplier
GNEE is a professional Chinese supplier with years of experience providing aluminum materials for the EV and industrial energy sectors. We understand that battery manufacturers cannot afford material failures.
We offer:
- A stable and reliable supply of high-purity raw materials.
High-precision slitting machines for accurate width control.
Strict surface cleaning to ensure your welding lines run smoothly.
Fast delivery times, typically between 7 and 25 days depending on the specification. - Customized dimensions tailored to your exact battery pack design.
Send us your target specifications (Thickness, Width, and Quantity) today! Our sales engineers will provide a detailed quotation and arrange material samples for your testing within 24 hours.
Contact GNEE now and secure your supply chain.