Copper Foil Resistance Diffusion Soldering Flexible Connection
Copper Foil Resistance Diffusion Soldering Flexible Connection is a flexible conductive component that uses multi-layer ultra-thin copper foil as the conductor base material, and integrates the ends of the laminated copper foil and the hard connection terminals through a resistance diffusion welding process.
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Product Introduction
Copper Foil Resistance Diffusion Soldering Flexible Connection
The product has excellent current-carrying capacity, ultra-low contact resistance and high power transmission efficiency, which effectively reduces power loss and avoids local overheating during high-current operation. The resistance diffusion soldering process ensures that the solder joints have strong mechanical strength, good thermal conductivity and anti-fatigue performance, which can withstand millions of times of bending without solder joint detachment or conductive failure, greatly extending the service life of the product.
Material advantages
Oxygen-free copper foil or high-purity tough copper foil is selected. Its oxygen content is extremely low, and there are few grain boundary impurities. It can form dense and continuous intergranular bonding during the diffusion welding process.
Extremely low body resistance and contact resistance
No solder barrier layer, the current path is a pure copper continuous structure.
01
Excellent thermal fatigue resistance
No solder cracking or crimping loosening under thermal shock of -40°C to 300°C for Copper Laminated Flexible Busbars.
02
Resistant to electrochemical corrosion
Single copper material, no risk of potential difference corrosion for Copper Foil Laminated Busbar Welding.
03
Flexible and customizable
Soft and rigid areas can be designed in the thickness direction to adapt to complex assembly paths for Copper Foil Busbar.
04
Manufacturing process and technical characteristics
Process principle
Use a polymer diffusion welding machine or special resistance welding equipment to apply specific pressure and current to the laminated copper foil. The Joule heat generated by the current causes the copper foil contact surface to reach a plastic state. Under the action of pressure, the contact surface undergoes microscopic plastic deformation, breaking the oxide film on the surface for Copper Foil Flexible Busbar For Rail Transit.
Technical barriers
Compared with traditional brazing, we do not need to add silver-based or copper-based solder, which fundamentally eliminates the risk of electrochemical corrosion caused by dissimilar metal contact. At the same time, compared with ordinary cold crimping, our thermal diffusion process can ensure that the resistance value at the connection is extremely low and stable, eliminating potential heating risks caused by poor contact.
Production advantages
The process is extremely repeatable and consistent. By digitally controlling welding parameters, we can ensure that the peeling force, conductivity, and appearance flatness of each batch of products are highly consistent, fully meeting the stringent quality standards of the automotive industry for Multi-Layer Copper Foil Bus Bar for Electricity System.
Detailed display
Interface micromorphology
Scanning electron microscope (SEM) pictures show the complete grain growth across the interface formed after diffusion welding, with no visible defects.
Dynamic display of flexible structures
High-speed photography shows that the resistance value change rate of the connection part is less than 1% after tens of thousands of cycles of bending.
Thermal imaging comparison
Compared with traditional welding of the same power resistor, under the same heat dissipation conditions, the hot spot temperature of the connection interface of this solution is reduced by 15-25°C.
Cross-section analysis
The photomicrograph after cross-section polishing clearly shows the uniform, dense, and hole-free metallurgical bonding zone between the copper foil and the component electrode.
FAQ
Q: DO YOU TEST ALL YOUR GOODS BEFORE DELIVERY?
A: Yes, we have 100% test before delivery.
Q: DO YOU TEST ALL YOUR GOODS BEFORE DELIVERY?
A: Usually, we accept bank T/T, irrevocable L/C at sight. For regular orders, we prefer 30%in advance,70% balance before shipment.
contact us
If you are looking for alternatives to crimping and soldering for Copper Foil Resistance Diffusion Soldering Flexible Connection, please send drawings or working conditions descriptions to our engineering team, and we will provide you with customized connection design and proofing verification support based on the diffusion welding process.
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