Flexible Copper Laminated Foil Connectors
The core structure of Flexible copper laminated foil connectors is composed of multiple layers of highly flexible metal foils stacked together, which are tightly bonded through processes such as polymer diffusion welding to form an integrated conductive path. Compared with traditional rigid busbars and round cables, copper foil flexible connections combine the high current carrying capacity of rigid busbars with the flexibility advantages of cables, perfectly adapting to various harsh engineering scenarios and becoming the preferred conductive connection components in fields such as new energy, power, and industrial automation.
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Product Introduction
In high-voltage electrical systems such as new energy vehicles, energy storage, and rail transit, traditional rigid busbars are limited by installation space, vibration stress, and thermal expansion and contraction, and can no longer meet the high-efficiency conductivity requirements under complex working conditions. Flexible copper laminated foil connectors, as a new generation of power transmission components, achieve a perfect balance of high conductivity, high flexibility, and high reliability through multi-layer metal foil stacking structure and special welding technology. They are the core solution to solve engineering pain points such as complex spatial wiring, vibration connection, and large electrical transmission.
Core advantages of the product
High flexibility and toughness
Flexible copper laminated foil connectors can achieve bending and twisting at any angle according to actual installation needs, perfectly adapting to compact and complex wiring scenarios such as new energy vehicle battery packs and precision electrical equipment, solving the pain point of traditional rigid busbars that cannot be flexibly wired, and greatly improving installation flexibility.
01
Low resistance and high current carrying capacity
The multi-layer flat conductor structure of Copper flexible busbar utilizes the skin effect, which enables the current carrying capacity to far exceed that of traditional circular cables under the same cross-sectional area. The current carrying efficiency is increased by more than 30%, effectively reducing equipment operating energy consumption.
02
Excellent seismic performance
The flexible structure of Multilayer copper foil flexible busbars can effectively buffer the vibration and impact stress during equipment operation, avoiding connection breakage caused by stress concentration. In high-frequency vibration scenarios such as new energy vehicles and rail transit, the service life can reach 3-5 times that of traditional rigid connections.
03
Easy and efficient installation
Compared to the complex processing and installation process of traditional rigid busbars, copper foil flexible connections can be directly bent and formed without additional processing, reducing installation time by more than 50% and minimizing labor costs and installation failure risks; At the same time, lightweight design reduces the overall weight of equipment and adapts to lightweight demand scenarios.
04
Production process and technical characteristics
Core polymer diffusion welding process:
The principle is to use heating and pressure to cause plastic deformation and atomic diffusion on the contact surface of multi-layer copper foil, forming a seamless integrated joint without solder, which is environmentally friendly and safe. The welding surface of this process is smooth and defect free, and the key parameters can be independently adjusted to ensure uniform and stable performance of the Flexible copper busbar. The failure rate is reduced by more than 62% compared to traditional argon arc welding, and it is suitable for various soft connection products. It can be welded in batches and has high production efficiency.
Insulation layer processing technology (customized as needed)：
The insulation layer of the Flexible insulated copper busbar currently mainly consists of two materials: special polyvinyl chloride (PVC) and thermoplastic elastomer (TPE). TPE has the characteristics of low smoke and halogen-free, and the insulation layer is mostly black or orange in color. In the application scenario of automotive high-voltage battery packs, the insulation sheath is made of TPE material. When ensuring fire resistance, mica tape containing soft mica with a thickness of 0.15mm is also used.
Manufacturing advantages：
Strong process controllability, precise parameter adjustment, ensuring consistent performance of batch Flexible copper laminated busbar; Outstanding customization ability, able to customize various specifications and structures as needed, suitable for non-standard scenarios; Strict quality control, with multiple international certifications and testing reports provided for each batch, in compliance with relevant industry standards.
Typical application areas
New energy vehicles
Connection between battery modules, connection between battery packs and high-voltage distribution boxes (PDUs), adapting to vibration and spatial changes.
01
Rail transit
Automotive copper busbars are used to connect pantographs with electrical equipment, traction converters with motors, and are resistant to vibration and weather.
02
Industrial automation
Copper laminated foil busbars are used for flexible wiring in robots, CNC machines, and automated production lines, enabling stable power transmission.
03
Electrical equipment
Flexible copper laminated foil connectors are used for cross connection and flexible interconnection in transformers, distribution cabinets, and switchgear.
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contact us
Xiamen Apollo Stamping Welding Technology Co., Ltd is a professional service provider for new energy metal processing solutions. We can help you accurately match your needs and maintain the bottom line of device safety. Welcome to consult us.
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