Multilayer Copper Foils Flexible Bus Bar
Multilayer Copper Foils Flexible Bus Bar is a flexible conductive component that is laminated with multiple layers of ultra-thin copper foil as the conductor body, and both ends are integrated with rigid terminals through welding or crimping processes. This product utilizes the structural characteristics of relatively sliding copper foil layers to achieve excellent three-dimensional flexibility and bending life, while maintaining low DC resistance and good current carrying capacity.
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Product Introduction
Multilayer Copper Foils Flexible Bus Bar
It is a flexible conductive component designed for high-reliability power transmission and high-power applications. Short copper foil soft connections are usually used in new energy vehicle battery packs to ensure efficient and stable current conduction between battery modules, while large copper foil soft connections are widely used in high-power electrical appliances and industrial equipment to provide stable current carrying capacity and excellent mechanical flexibility for the system.
Core product structural characteristics
Laminated copper foil structure
Copper Flexible BusBar adopts multi-layer precision lamination of high-purity electrolytic copper foil with a thickness of 0.05mm-0.2mm, and achieves inter-layer metallurgical bonding through molecular diffusion welding without solder intervention, fundamentally eliminating the risk of contact resistance and electrochemical corrosion.
Flexible deformation ability
The bending radius can reach 2-3 times the material thickness, allowing ±15mm displacement compensation in the XYZ three-axis direction, perfectly adapting to the deformation of the battery pack during charging and discharging and the mechanical vibration during vehicle operation.
Surface plating process
Optional nickel plating, silver plating, or tin plating, salt spray test can last up to 96-240 hours, meeting the anti-oxidation and corrosion resistance requirements in harsh environments for Tin Plated Copper Bus Bar.
Technical features and design advantages
Flexible compensation design
Flexible Copper Laminated Foil Connectors structure allows the busbars to bend freely within a certain angle and displacement range, effectively absorbing the mechanical stress caused by battery module expansion, equipment vibration and installation tolerances.
Thermal management optimization
Compared with solid copper bars, multi-layer copper foil provides a larger surface area and internal gaps, which is conducive to air convection and heat dissipation. Under sustained high current conditions, the temperature rise of copper foil soft connections is usually lower than that of traditional solutions.
High space utilization
The flexible structure allows the Laminated Flexible Busbar for New Energy Vehicles to be routed along irregular paths, adapting to compact equipment interior spaces. This advantage is particularly obvious for battery modules or power cabinets with limited space.
Electromagnetic compatibility (EMC)
The laminated parallel conductor structure can effectively offset part of the magnetic field, reduce electromagnetic radiation interference, and meet the EMC requirements of automotive electronics and precision equipment for Copper Foil Flexible Connection.
Production process
Copper material selection and inspection
Copper Flexible BusBar is tested for conductivity, thickness and flexibility to ensure that the material performance meets the design requirements.
Overlay and cut
Multilayer Bus Bar is precisely laminated according to the designed size and cut into standard or customized sizes by a high-precision cutting machine.
diffusion welding
Press Welded Copper Foil Flexible Busbar is diffusion welded under high temperature and high pressure conditions to ensure strong interlayer molecular bonding and stable electrical properties.
Deep adaptation to application scenarios
Module-level connection
length 50mm-300mm, suitable for series and parallel connection of square case cells and cylindrical cells to solve cell expansion displacement and vibration stress.
Pack-level power distribution
connects the main positive, main negative and BDU power distribution units. The Copper Flexible BusBar design absorbs the torsional deformation of the vehicle chassis.
Maintenance convenience
The detachable terminal design supports non-destructive disassembly during battery pack maintenance, reducing full life cycle service costs for Nickel Copper Foil Strip For Flexible Packaging Battery Connectors.
contact us
We do not compete with low prices, but provide complete engineering supporting capabilities from structural simulation, sample trial Multilayer Copper Foils Flexible Bus Bar to batch process finalization - if you need a DFM solution based on your specific current, space and life requirements, please contact our application engineering team directly.
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