Flexible Copper Foil

 

Our flexible copper foil busbars are constructed using high-grade C1100 T2 red copper strips to guarantee optimal electrical performance and mechanical fatigue resistance. Multiple thin copper foils (typically 0.05mm, 0.1mm, or 0.2mm) are stacked to specified cross-sectional areas to carry heavy continuous currents while offering exceptional physical flexibility. The contact ends undergo high-pressure solid-state joining without filler materials, maintaining uniform current distribution across the entire contact surface.

 

The stamping and preparation of connection terminals are executed using automated high-speed presses. We design and maintain custom progressive dies to perform punching, notch cutting, and terminal shape forming in a single continuous setup, eliminating burrs and surface contamination.

 

Flexible Copper Busbar Technical Specifications

 

Parameter	Raw Material Grade	Electrical Conductivity
Single Layer Thickness	Dimensional Tolerance	Dielectric Voltage Resistance
Flame Retardancy	Specification Standard	C1100 T2 Pure Copper (JISH3100/ASTM B152)
EN 13601/IEC 60228	Standard Foil Gauge	ISO 2768-mk/Customer Drawing
IEC 61439/UL 758	UL 94 Standard	Apollo Factory Capability
Cu ≥ 99.90%, Oxygen Content< 30ppm	100% IACS (> 58.0 MS/m)	0.05 mm, 0.08 mm, 0.10 mm,0.20 mm
+0.01 mm on stamped mounting holes	>15 kV/mm (Epoxy Dip /Heat Shrink)	UL 94 V-0 compliant insulation

 

 

To achieve zero-resistance joining at the contact ends, Apollo deploys advanced diffusion welding technology. Under controlled high temperature and pressure, copper atoms diffuse across the foil interfaces to create a homogeneous metallic structure. This process eliminates intermetallic voiding, oxidation, and micro-arc risks inherent to conventional brazing methods.

 

For insulation protection in tight battery packs and switchgear, we offer electrostatic epoxy powder coating, fluid bed dipping, and flame-retardant polyolefin heat-shrink tubing. Terminal contact surfaces are finished with heavy electroplated tin (3–8µm) or silver (3–10µm) layers to prevent oxidation and minimize fretting corrosion under elevated thermal conditions.

 

 

Quality assurance at Apollo aligns strictly with automotive and industrial electrical standards under our certified IATF 16949:2016 and ISO 9001:2015 management systems. Dimensional verification is performed using Hexagon CMM (3D Coordinate Measuring Machine) and Optical Coordinate Measuring Systems with measurement accuracy up to 0.0007mm.

 

Every production batch undergoes comprehensive electromechanical testing, including 100% micro-ohm contact resistance checking, temperature rise testing under rated continuous current, dielectric breakdown testing, and salt spray exposure (NSS > 720 hours for plated layers). We deliver a complete PPAP Level 3 package containing Control Plans, PFMEA, CPK process capability charts, and material trace reports for every OEM project.

 

 

 

 

Ready to optimize your high-current power connection system? Submit your 2D/3D CAD drawings (.STEP, .STP, .DWG) and operating specifications (rated current, voltage, resistance, plating thickness) to Xiamen Apollo today. Our engineering department will deliver a comprehensive DFM feasibility analysis, material optimization report, and a direct factory quotation within 24 hours.