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Copper Laminated Foils Connector

Our Copper laminated foils connector, with its layered design of "high-purity copper foil layer + insulating layer + reinforcing adhesive layer," retains the excellent conductivity of copper while offering flexible adaptability. This design addresses the issues of "rigidity making installation difficult and single-layer designs being prone to damage," making it the ideal "flexible connection solution" for complex applications, helping customers reduce installation time and maintenance costs, and improve the reliability of electrical connections in their equipment.

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Product Introduction

The copper laminated foils connector represents a significant breakthrough in electrical connection technology, designed specifically for applications requiring high resistance to vibration, extreme temperature variations, and long-term reliability. This Copper Foil Flexible Busbar features a unique laminated composite structure, combining high-purity electrolytic copper foil with a high-performance elastic material through a precise manufacturing process. This results in an innovative connection solution that offers excellent electrical conductivity, superior fatigue resistance, and stable mechanical properties.

Key Selling Points

1. Multi-layer Copper Foil Composite Structure: The Perfect Balance of High Conductivity and High Flexibility
Unlike traditional single-layer copper busbars or wiring harnesses with their inherent rigidity, the Multilayer Copper Foils Flexible BusBar achieves a synergistic optimization of electrical conductivity and mechanical flexibility through the alternating layering of ultra-thin copper foil (single-layer thickness ≤ 0.05mm) and flexible insulating materials.

High Conductivity: Using 99.9% high-purity Copper Flexible BusBar, the multi-layer parallel structure increases current-carrying capacity by over 30% (with the same cross-sectional area), effectively reducing temperature rise during high current transmission and preventing performance degradation due to overheating.

High Flexibility: The composite structure allows a bending radius of up to 10 times the copper foil thickness (e.g., a 0.1mm thick connector has a minimum bending radius of 1mm), enabling easy three-dimensional wiring to meet compact device design requirements and solving the stress concentration problems of traditional rigid connectors under dynamic conditions.

2. Integrated Composite Molding Process: Stable Structure and Superior Protection
The Press-welded Flexible Copper Connection utilizes an integrated hot-pressing and precision coating process, ensuring no bubbles or delamination between the Copper Laminated Foil Busbar and insulation layers, resulting in a dense composite structure that fundamentally eliminates the risk of poor connection or detachment common with traditional welding or crimping.

Structural Stability: The bonding strength between the copper foil and insulation layer is ≥8N/mm, with no cracking or resistance changes after 100,000 bending tests, capable of enduring long-term mechanical stress (e.g., dynamic loads on battery packs in new energy vehicles on bumpy roads).

Environmental Resistance: The outer insulation material uses high-temperature resistant polyimide (200°C long-term temperature resistance) or flame-retardant PET (UL 94 V-0 grade), providing moisture, salt spray, and chemical corrosion resistance, enabling stable operation in extreme environments from -40°C to 150°C, suitable for harsh industrial and automotive applications.

Manufacturing Technology of Copper laminated foils connector

Application Scenarios

Power Battery Modules and Energy Storage Systems	Used for inter-cell or inter-module connections within battery packs. The flexible design accommodates battery expansion, and the laminated structure ensures stable high-current transmission.
Electric Vehicle Motor Controllers (MCU)	Connects IGBT modules to the DC bus, withstanding high-frequency PWM currents and thermal cycling. Low inductance design reduces EMI and improves system efficiency.
Photovoltaic Inverters and Power Conversion Systems (PCS)	Provides low-loss connections between power modules, enhancing energy conversion efficiency and complying with safety standards.
Rail Transportation Traction Systems	Used in high-vibration environments such as traction inverters and auxiliary power supplies. The Copper Foil Bus Bar has passed vibration and impact tests to ensure long-term reliable operation.
Industrial UPS and High-Power Power Supplies	Provides efficient connections between rectifiers and inverter modules, reducing system temperature rise and improving equipment reliability and lifespan.