Flexible Insulated Copper Busbar Soft Connections
Xiamen APOLLO's flexible insulated copper busbar soft connections utilize multi-layer ultra-thin copper foil technology, achieving exceptional current density (up to 50A/mm²) and minimal AC loss. Our proprietary lamination process ensures superior thermal management (-55°C to 180°C range) and vibration resistance, with custom-designed profiles available for specific integration requirements in high-frequency applications.
- Fast Delievery
- Quality Assurance
- 24/7 Customer Service
Product Introduction
Flexible insulated copper busbar soft connections resolve vibration-related connection issues and spatial restrictions in modern electronics by substituting rigid cables with lightweight, customizable conductive solutions. These components remove the need for separate insulation sleeving, incorporate inherent arc flash protection, and endure repeated bending in diverse applications from automated industrial equipment to solar tracking installations.
working principle
Flexible Insulated Copper Busbar Soft Connections operate by employing stacked copper layers to form a highly conductive and flexible path for current. The insulating layer ensures protection against electrical shorts and environmental wear. This configuration enables the busbar to flex and absorb vibrations without affecting its electrical efficiency, which makes it highly suitable for dynamic applications such as electric vehicles and industrial machinery, where both movement and consistent performance are essential. This design strikes a balance between flexibility and reliability, ensuring optimal functionality even in environments subject to motion and stress.
application fields
Aerospace Avionics Power Distribution
The insulated flexible busbar provides critical power transmission in aircraft navigation and communication systems, offering extreme vibration resistance and reliability under temperature fluctuations from -55°C to 200°C.
Marine Propulsion Systems
Flexible copper busbar laminated foils connector replaces rigid cabling in ship power networks, resisting saltwater corrosion and maintaining stability in high-humidity environments.
Data Center Backup Power Units
The flexible laminated soft connector delivers uninterrupted power transfer in UPS systems, supporting 24/7 operation with minimal voltage drop and heat generation in confined server racks.
production process
| Material Preparation | High-purity electrolytic copper foils are precision-cleaned and surface-treated to ensure optimal conductivity for the flexible laminated soft connector manufacturing process. |
| Lamination Process | Multiple copper layers are stacked with insulating films (e.g., PET or silicone) and fused under high temperature and pressure to form a unified flexible copper busbar laminated foils connector structure. |
| Punching and Shaping | The laminated composite is die-cut into specific shapes using precision punches, creating custom geometries for different application scenarios. |
| Plating and Insulation | Surface plating (tin/nickel) is applied for corrosion resistance, followed by insulation coating or sleeving for enhanced electrical protection. |
| Quality Testing | Each unit undergoes rigorous electrical (impedance/hipot) and mechanical (flex cycle/vibration) tests to ensure compliance with GB/T and industry standards. |
Our strengths
1. Technical Superiority vs Competitors
Our flexible insulated copper busbar delivers 45% higher current density and 60% longer flex life than industry standards, with laser-welded layers ensuring zero delamination under extreme conditions. These advantages make them ideal for high-performance applications where reliability is critical.
2. Comprehensive Service Assurance
We provide ISO 9001 and IATF 16949 certified insulated flexible busbar, with a proven service life exceeding 10 years. Our clients include global leaders like Tesla, BYD, Littelfuse, SIBA and Mersen. We support global logistics via air, sea, and land transport. Our flexible laminated soft connector solutions offer custom design support for specialized requirements.
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