Reliable Copper-to-Aluminum Connection Solution
Lower cost. Safer CU-AL connections.
Why Use Aluminum Cables in Solar Projects?
With rising copper prices and increasing cable theft risks, aluminum cables are becoming the preferred choice for utility-scale solar projects.
Lower Cost
Up to 30-50% lower cost than copper.
Easy Installation
Lightweight, easier installation.
Theft Resistant
Lower theft risk due to lower scrap value.
Utility-Scale Ready
Suitable for large-scale PV plants.
Copper-to-Aluminum Connection Solution of SUNKEAN
Choose the connection option that fits your PV system architecture.
Option A - SK-A Series
The SUNKEAN SK-A aluminum connection solution is designed to support lightweight, cost-effective, and high-efficiency photovoltaic cable systems. By leveraging aluminum conductor technology, the solution helps reduce material costs while meeting the performance requirements of modern solar energy infrastructure.
View SK-A Connector
Option B - SK-TC CU-AL Transition
Designed for large-scale photovoltaic power plants, the SUNKEAN SK-TC Cu-Al transition interconnection solution enables reliable copper-to-aluminum cable connections with improved installation flexibility and optimized system cost. Engineered for field adaptability, it simplifies on-site crimping and supports efficient deployment in complex solar project environments.
View SK-TC Harness
Option C - Aluminum Cable
Lightweight, cost-effective and theft-resistant aluminum alloy PV cables, pre-assembled CU-AL conversion harnesses, copper-to-aluminum connectors and optimized crimping tools form an integrated aluminum cable connection system that eliminates installation errors and ensures consistent connection quality.
View Aluminum CablesKey Technology
Engineered at the material level for stable, long-life copper-to-aluminum joints.
Solid-State Friction Welding
The copper-to-aluminum joint adopts friction welding (solid-state bonding), which operates at low temperatures to minimize thermal damage to the cable. Over 25 years, conductivity degradation is less than 0.5%, and tensile strength is verified through pull and impact testing.
Advanced Multi-Layer Protection Coating
The joint surface is protected by a three-layer gradient structure: diffusion layer, chemical nickel plating layer, and hot-dipped tin anti-oxidation layer. An electroplating hole design ensures uniform coating, and no corrosion occurs in the contact area after a 96-hour 5% salt spray test.
Why Choose SUNKEAN
A trusted manufacturing partner for solar copper-to-aluminum connectivity.
Advanced Manufacturing Capability
In-house production lines with precision friction welding, coating and crimping processes for consistent copper-to-aluminum connection quality.
Strict Quality Control
Every joint and harness is electrically tested and batch-documented, with salt spray and tensile verification against recognized standards.
Global Project Experience
Thousands of CU-AL connectors deployed across utility-scale solar farms, delivering proven long-term performance in the field.
Trusted by Solar Projects Globally
Real deployments across utility-scale PV plants.
PV Las Violetas (Chile)
852 sets CU-AL connectors deployed and 51 km aluminum cable installed, reducing cable costs while ensuring stable long-term performance.
PV Los Quilos (Chile)
1,481 sets CU-AL connectors deployed and 112 km aluminum cable installed, improving installation efficiency with reliable copper-aluminum connections.
Chile Solar Farm
6,000 sets CU-AL connectors deployed and 120 km aluminum cable installed, enabling large-scale deployment with consistent connection quality.
FAQ on Copper to Aluminum Connection
How much cost savings can SUNKEAN's copper-to-aluminum connection solution deliver?
Compared to a full-copper system, this solution reduces costs by up to 58%. In a 1 GW PV power plant project, the savings can exceed USD 2,750,000.
How is SUNKEAN's copper-to-aluminum conversion harness designed to ensure stability and safety?
The harness uses a copper-aluminum-copper structure: copper conductors on both ends with an aluminum conductor in the middle, plus a plastic connector housing. It supports high currents and allows quick on-site crimping at the aluminum end for simplified installation.
What welding process is used for the copper-to-aluminum joint, and how reliable is it?
The connection adopts friction welding (solid-state bonding), which operates at low temperatures to minimize thermal damage to the cable. Over 25 years, conductivity degradation is less than 0.5%, and tensile strength is verified through pull and impact testing.
How does the copper-to-aluminum connector maintain corrosion resistance in harsh environments?
The joint surface is protected by a three-layer gradient structure: diffusion layer, chemical nickel plating layer, and hot-dipped tin anti-oxidation layer. In a 96-hour 5% salt spray test, no corrosion occurred in the contact area.
