Laminated Copper Flexible Connectors
The engineering positioning of Laminated Copper Flexible Connectors is to provide a "flexible, highly reliable, and low-loss" connection solution for high-demand power transmission scenarios. The core solution is to solve the core pain points of traditional rigid connections in complex working conditions, while adapting to various compact and integrated engineering design requirements.
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Product Introduction
In the field of modern power transmission and electrical connections, the upgrading of industries such as new energy and smart grids is driving the development of connecting components towards high efficiency, reliability, adaptability to complex working conditions, and compact layout. Traditional rigid connections are prone to poor contact and overheating in scenarios such as vibration, thermal expansion, and contraction, which can affect system stability and increase maintenance costs.
Laminated Copper Flexible Connectors are designed specifically to address the aforementioned pain points. With advanced technology and optimized structure, they excel in flexibility, conductivity efficiency, and reliability. They are the preferred power connection solution for high-end fields such as new energy and rail transit, providing stable connection guarantees for engineering systems throughout their lifecycle.
Core engineering pain points to be solved
Difficulties in adapting to vibration and shock
In scenarios such as industrial equipment operation, rail transit vehicle travel, and outdoor operations of new energy equipment, continuous vibration can easily cause rigid connections to loosen, solder joints to detach, resulting in increased contact resistance, local overheating, and even circuit breakers. Laminated Copper Flexible Connectors, with its flexible structure consisting of multiple layers of thin copper foil, can effectively absorb vibration energy, buffer mechanical impact, avoid stress concentration at the connection site, and significantly reduce the risk of vibration induced failures. It has been tested that the vibration fatigue life is more than three times longer than that of rigid copper bars.
01
Difficulty in compensating for thermal expansion and contraction
The temperature difference (-40 ℃~120 ℃) generated during the operation of high-power equipment can cause thermal expansion and contraction of conductors, and rigid connections cannot achieve deformation compensation, which can easily lead to insulation layer damage, conductor cracking, and other problems. Multilayer Copper Foils Flexible BusBars can adapt to the size expansion and contraction caused by temperature changes through their own flexible deformation, eliminate the damage of thermal stress to the connection structure, and ensure the stability of the connection in high and low temperature environments.
02
Difficulty in a limited spatial layout
Modern high-end equipment such as electric drive systems for new energy vehicles and miniaturized energy storage modules require extremely high utilization of internal space, and the flexibility of rigid copper bar layout is poor, making it difficult to adapt to complex installation paths and compact spaces. Copper Flexible BusBar can achieve multi angle bending (minimum bending radius ≥ 200mm) according to engineering layout requirements, without the need for complex adapter components, greatly improving space utilization and assisting in equipment miniaturization and integrated design.
03
Difficulty in compatibility with installation misalignment
During the installation process on the engineering site, equipment benchmark deviation and installation errors can easily lead to inaccurate docking of rigid connections, requiring repeated adjustments or even reprocessing, delaying the construction period. The flexible characteristics of Flexible BusBar Copper are compatible with installation misalignment errors of ± 5mm, reducing installation accuracy requirements, improving construction efficiency, and shortening project delivery cycles.
04
specific parameters
Sectional area
According to different application scenarios and current carrying requirements, the cross-sectional area of Multi Layer Copper Foil Flexible BusBar can be flexibly customized between 10-1000 square millimeters. A larger cross-sectional area can carry larger currents, making it suitable for fields such as industrial power transmission and high-voltage systems for new energy vehicles that require high current carrying capacity.
Resistance value
At a standard ambient temperature of 20 ℃, the resistance value of a unit length (such as 1 meter) of Press welded Flexible Copper Connections is usually between 0.01-0.1 Ω, depending on the thickness, number of layers, and quality of the diffusion soldering process of the copper foil. The low resistance characteristic ensures the high efficiency of power transmission and reduces the heat loss caused by resistance.
Current carrying capacity
The current carrying capacity of Flexible Battery Pack Copper Connectors is closely related to factors such as cross-sectional area, copper foil thickness, and ambient temperature. Taking a flexible connection with a cross-sectional area of 100 square millimeters and a copper foil thickness of 0.15mm as an example, its continuous current carrying capacity can reach around 300-400A at an ambient temperature of 40 ℃. In practical applications, it is necessary to evaluate and adjust the current carrying capacity reasonably based on the specific working environment and heat dissipation conditions.
Our Certifications
Between the surging current of photovoltaic modules and the surging energy of energy storage batteries, Xiamen Apollo Stamping Welding Technology Co., Ltd. has built a quality moat with global certification and exclusive patents. We have not only obtained ISO 9001:2015 international certification (currently applying for IATF16949 automotive industry international quality certification system), but also redefined the precision and reliability of new energy components with three core patented technologies.
contact us
You can conduct technical benchmarking based on existing Laminated Copper Flexible Connectors parameters. Our professional team has unique professional knowledge and rich experience, which enables us to tackle complex projects with ease and efficiency. Please feel free to contact us.
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