Copper Foil Flexible Connection
Copper foil flexible connection is a flexible power transmission component made by stacking multiple layers of metal foil and using special welding or crimping processes. Unlike traditional rigid busbars, it has the characteristics of bendability and good flexibility, which can achieve efficient power transmission in complex spatial environments, effectively solving the limitations of traditional busbars in installation and use.
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Product Introduction
Copper foil flexible connection is not simply a process of laminating copper materials, but rather a precise controlled diffusion welding process that transforms multi-layer T2 soft copper foil into an overall conductive material with anisotropic mechanical properties - compressible deformation in the thickness direction to absorb vibrations, bendable torsion in the length direction to adapt to space, and rigid in the width direction to maintain a low resistance cross-section. The structural characteristics of this "combination of rigidity and flexibility" make it an indispensable key component in modern battery packs, energy storage systems, and high-end power equipment due to its limitations.
Design advantages
High flexibility
Copper foil flexible connection can bend and twist at any angle according to the actual installation space, greatly improving the flexibility of installation, especially suitable for devices and systems with compact space and complex wiring.
Low resistance and high current carrying capacity
The structural design of Multilayer copper foils flexible busars makes the current distribution more uniform, effectively reducing resistance and improving current carrying capacity, which can meet the power transmission needs of high-power equipment.
Good seismic performance
During the operation of the equipment, the Copper flexible busbar can effectively buffer the stress caused by vibration and impact, avoiding the breakage or damage of the connection parts due to stress concentration, and improving the reliability and stability of the system.
production process
Foil cutting and stacking
Strictly follow the design requirements, accurately cut the copper foil according to the stacking quantity of 2-12 pieces and the specified copper strip specifications, ensure that the size error of the Flexible copper busbar is controllable, and then stack it neatly according to the standard process. This precise cutting and stacking process ensures uniform current distribution and optimal electrical performance across all layers.
01
Polymer diffusion welding
Flexible copper laminated busbar uses professional diffusion welding equipment to achieve atomic diffusion at the interface of stacked copper foils under high temperature and high pressure environments, achieving metallurgical bonding and ultimately forming an integrated conductive body. The entire process does not require the addition of any solder, ensuring the conductivity and structural stability of the welded joint.
02
Surface treatment and insulation coating
Tin plating or nickel plating processes are selected for surface treatment according to customer needs, with the thickness of the tin plating layer strictly controlled at Sn 0.5-1.0 μ m to enhance the product's oxidation resistance and corrosion resistance; The insulation coating is based on the product structure and customer requirements, using PVC, TPE or Micatape insulation materials.
03
Forming and full inspection
Precisely bend and form according to the design drawings of Flexible busbar copper to meet actual installation requirements; After molding, all products undergo 100% full inspection, including withstand voltage testing, insulation resistance testing, appearance inspection, and dimensional inspection, to ensure that each product meets the standards and prevent unqualified products from leaving the factory.
04
Application scenarios
New energy vehicle
In new energy vehicles, Automotive copper busbars are employed for flexible conductive connections between battery modules, as well as between battery packs and high-voltage electrical systems. They can adapt to vibrations and spatial variations during vehicle operation, thus ensuring steady power transmission.
Rail transit
The Laminated flexible busbar is utilized in train electrical systems, including the connections between pantographs and electrical devices, as well as between traction converters and motors. It is capable of enduring constant vibration and impact during high-speed train operation, thereby guaranteeing the reliability of power transmission.
Industrial automation
Copper foil flexible connections are employed in automation equipment, robots, CNC machines, and production lines to enable flexible wiring between components like power supplies, controllers, and motors, effectively overcoming installation constraints posed by compact spaces.
Engineering Team
Our team is a dynamic and highly skilled group of professionals. The team has the ability to provide multi-process integration services, covering multiple production processes such as cold heading, riveting, stamping, welding, and CNC machining, and can efficiently undertake the integrated manufacturing needs of complex components. Relying on 24 branch local offices worldwide, we have established a 365 days & 24 hours timely service mechanism, which can quickly respond to various customer demands.
Contact Us
Inquiry does not constitute a binding commitment to place an order. We sincerely welcome all kinds of inquiries about our products, prices, specifications and related services, and will reply to you with professional and detailed information in a timely manner.
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