Flexible Laminated Copper Busbar Copper Connector
100% IACS Copper: C11000 foils yield maximum electrical conductivity.
Diffusion Welded: Solid-state joint eliminates resistance spikes.
Rapid Prototyping: Free samples in 1-2 days; T1 dies in 20 days.
In-House Tool & Plating: Full control from die design to tin/silver.
IATF 16949 Quality: ISO 9001, RoHS, and REACH certified factory.
Low Inductance (<10nH): Protects 800V SiC drive inverter circuits.
Fast Mass Production: Guaranteed 15-20 days volume order delivery.
- Fast Delievery
- Quality Assurance
- 24/7 Customer Service
Product Introduction
These Flexible Laminated Copper Busbar Copper Connector are constructed by stacking ultra-thin, high-purity C11000 copper foils (ranging from 0.05mm to 0.3mm in thickness) and joining them at the contact areas using solid-state molecular diffusion welding or resistance pressure welding. Designed to absorb thermal expansion, mechanical vibration, and structural installation misalignments, these connectors effectively prevent stress accumulation on sensitive power electronics terminals. The flexible central section maintains low electrical resistance while accommodating multi-axis dynamic displacement within high-current power distribution systems. We offer comprehensive OEM customization services, including tooling development, automated copper foil stacking, selective plating, and automated insulation sleeve assembly. From raw copper foil processing to finished assemblies, we provide specialized solutions for sectors such as electric vehicle (EV) power distribution, energy storage systems, and industrial transformers. Our engineering team conducts thorough Design for Manufacturability (DFM) assessments to optimize cross-sectional current density and minimize stray inductance.
Technical Specifications & Material Standards
| Parameter Category | Technical Attribute / Specification | Base Material / Value Range | Engineering Standard | Testing & Quality Method |
| Material & Purity | Raw Copper Foil Grade | C11000 / E-Cu (Cu ≥ 99.90%) | GB/T 5231 / ASTM B152 | Spark OES Chemical Analysis |
| Electrical Performance | Electrical Conductivity | ≥ 100% IACS (58.0 MS/m) | IEC 60028 | Eddy Current Conductivity Meter |
| Layer & Joint Specs | Foil Layer Thickness & Joint | 0.05–0.30 mm (Diffusion Welded) | ISO 2768-m | Micro-sectioning & Pull-off Test |
| Plating & Surface | Contact Finish & Thickness | Electro-Tin / Silver (3–12 µm) | ISO 2093 / ASTM B700 | X-Ray Fluorescence (XRF) Gauge |
| Insulation & Safety | Dielectric Insulation Rating | Epoxy / Polyimide (>15 kV/mm) | UL 94 V-0 / IEC 60243-1 | High-Voltage Hipot Spark Tester |
Application Scenarios & Industry Integration
EV Battery Pack Interconnects
Connects module-to-module and module-to-BMS terminals, isolating cells from vehicle road vibration and thermal strain for Flexible Copper Busbar for Automotive Power Distribution.
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800V Traction Inverters & PDUs
Functions as a low-inductance connection between SiC/IGBT power modules and DC-link capacitors within compact drive units for Laminated Flexible Busbar for New Energy Vehicles.
02
Commercial & Utility Energy Storage (ESS)
Handles high-current busing between battery racks and power conversion systems (PCS) under continuous duty cycles.
03
Wind & Solar Inverters
Transmits high amperages from PV combiner boxes to central inverter bus networks with minimal thermal losses for Flexible Laminated Copper Busbar Copper Connector.
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Industrial Transformer Connections
Acts as a flexible copper foil connector transformer part, the Copper Foil Busbar Used for High Current Voltagemitigating mechanical stress from magnetic hum and structural thermal expansion.
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Frequently Asked Questions
Q: How does diffusion welding prevent contact resistance spikes in laminated copper shunts?
A: Diffusion welding applies high heat and pressure without filler metal, forcing copper atoms to interdiffuse across foil interfaces. This creates a solid copper block at the terminal ends with zero internal voids, maintaining conductivity identical to solid copper bar and eliminating interface oxidation over prolonged thermal cycling.
Q: What insulation coating processes are available for complex 3D-formed flexible busbars?
A: We utilize automated fluid-bed epoxy powder dipping or precision-wrapped Kapton polyimide film depending on voltage limits. Epoxy spray yields a uniform, conformal 0.3mm–0.8mm shell rated above 15kV/mm withstand voltage, while wrapped Kapton delivers high dielectric strength in tight clearance profiles without compromising flexibility.
Q: What is your standard prototype turnaround, and can you supply full PPAP Level 3 documentation?
A: Our T1 prototype turnaround for custom laminated flexible busbars is 10 working days, utilizing soft tooling for fast validation. Serial production orders are backed by full PPAP Level 3 submissions, including IMDS registration, dimensional CMM reports, material composition analysis, and CPK data.
Contact Us
Need a custom Flexible Laminated Copper Busbar Copper Connector engineered for your high-voltage electrical assembly?
Submit your 2D/3D CAD drawings (STEP, IGES, DWG) along with target current capacity and operating temperature parameters. Our engineering team delivers a comprehensive DFM evaluation, structural layout recommendation, and factory-direct quotation within 24 hours.
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