Copper Foil Flexible Laminated Copper Busbar
Copper Foil Flexible Laminated Copper Busbar are high-current conductive components formed by laminating multiple layers of high-purity copper foil with insulating materials. They are specifically designed for high-dynamic operating conditions such as new energy vehicles and energy storage systems. Their core function is to achieve low-resistance, high-reliability high-current transmission within a limited space, while also adapting to mechanical stresses such as vibration and bending, thus replacing traditional rigid copper busbars to solve complex layout challenges.
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Product Introduction
Copper Foil Flexible Laminated Copper Busbar is a conductive bar made of multiple layers of thin copper foil stacked, laminated, and optionally insulated. It is used to replace rigid copper bars and achieve reliable connections in applications requiring vibration resistance, strong spatial adaptability, and high current transmission.
Working principle
Current Conduction Mechanism
Multiple layers of ultra-thin copper foil arranged in parallel increase the conductive cross-sectional area, capable of carrying currents from 100A to 5000A. At 20℃, the Copper Flexible Busbar with Insulated Tube's resistivity is as low as 1.724μω・cm, resulting in low loss and high transmission efficiency, superior to ordinary flexible cables.
Flexibility Principle
Alternating lamination of 0.05mm-0.3mm ultra-thin copper foil with flexible insulation layers allows for slight relative movement, absorbing mechanical deformation and adapting to dynamic operating environments, ensuring stable Copper Foil Flexible Busbar Connectors operation.
Insulation and Thermal Management Principle
Interlayer insulation layers prevent short circuits for safety; the multi-layer structure increases the Copper Foil Battery Busbar Connector's heat dissipation area. During normal operation, the product's temperature rise is ≤50℃, preventing insulation aging.
Core advantages
High Current Carrying Capacity
Utilizing a multi-layered copper foil parallel arrangement design, the Busbar's current carrying capacity is increased by 15%-30% compared to traditional rigid bars. It can stably carry currents from 100A to 5000A with low resistance loss, perfectly meeting the high-power operation requirements of new energy equipment.
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Flexibility and Vibration Resistance
Flexible and adaptable to various installation scenarios, the minimum bending radius is designed to fit the copper foil thickness. The Copper Foil Battery Busbar Connector has excellent vibration resistance, enabling long-term stable operation in vibration environments of 10-2000Hz, adapting to various installation needs.
02
Excellent Thermal Management
Leveraging the multi-layered structural design to increase the heat dissipation area, the Copper Foil Flexible Busbar For Rail Transit's heat dissipation efficiency is improved by 20%-40% compared to traditional bars. The operating temperature rise is ≤50℃, effectively delaying insulation aging and extending the product's service life to 15-20 years.
03
Reliable Insulation Performance
The Copper Foil Busbar's insulation breakdown voltage is ≥15kV/mm, with excellent insulation resistance, effectively eliminating the risk of interlayer short circuits. It is suitable for high-voltage operating environments and possesses good arc resistance and anti-aging capabilities.
04
Compact and space-saving design
Compared with traditional busbars, the Copper Foil Flexible Laminated Copper Busbar volume is reduced by 30%-50% and the weight is reduced by 20%, which can flexibly adapt to narrow installation spaces, simplify the installation process, and is suitable for space-sensitive new energy equipment.
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Frequently Asked Questions
What is the service life of a copper foil busbar?
Under normal operating conditions (temperature -50℃~150℃, no severe vibration, no corrosive environment), its service life can reach 15-20 years, which is much longer than that of traditional rigid busbars (about 10 years). If it is in a harsh environment (high corrosion, high frequency vibration), its service life can be maintained for more than 10 years through surface coating treatment and optimized insulation materials.
How to solve the delamination problem of copper foil flexible busbars?
Delamination is mainly caused by aging of the adhesive material, improper installation, or environmental corrosion. When selecting a model, choose an adhesive with high temperature resistance and high bonding strength; avoid excessive bending or pulling during installation; in corrosive environments, choosing tin-plated or silver-plated copper foil and ensuring overall insulation protection can effectively prevent delamination.
Can the size and shape of flexible laminated copper busbars be customized?
Yes. The number of copper foil layers (5-50 layers), thickness (0.5-5.0mm), width (10-200mm), and bending shape can be customized according to the installation space, current requirements, and connection method of the equipment, fully adapting to the personalized needs of different equipment.
What are its advantages compared to ordinary flexible cables?
Ordinary flexible cables have low current carrying capacity, high resistance loss, and poor heat dissipation. In contrast, copper foil flexible laminated copper busbars have a current carrying capacity 2-3 times that of flexible cables of the same cross-sectional area, reduce resistance loss by more than 50%, and offer higher heat dissipation efficiency, a more compact structure, and are suitable for high-voltage, high-current applications, with a longer service life.
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