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Multilayer Copper Foils Flexible BusBar

Multilayer Copper Foils Flexible BusBars is a specialized power transmission component fabricated through precision manufacturing processes. Typically constructed from copper with multilayer laminated foil stacks, this innovative design employs advanced welding or crimping techniques to integrally bond adjacent foil layers, creating a unified conductive path. The copper construction delivers exceptional electrical conductivity and superior corrosion resistance (meeting ASTM B152 standards), making it particularly suitable for mission-critical applications requiring high-current density and reliable performance in harsh operating environments.

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Product Introduction

Multilayer Copper Foils Flexible BusBar is an advanced power transmission component engineered through precision manufacturing processes. Distinguished from conventional rigid busbars, Flexible BusBar's bendable and highly flexible design enables efficient electrical conduction in geometrically constrained spaces, effectively overcoming installation and operational limitations inherent to traditional solutions. Structurally, Copper BusBars comprises multilayer laminated copper foil stacks (typically 0.05–0.2mm thickness per layer) bonded via laser welding or diffusion bonding techniques, forming a unified low-impedance conductive path (<5μΩ/m).

Multilayer Copper Foils Flexible BusBar

Technical Specifications

Conductor Specifications

Material: T2 soft copper strip (C11000, Cu≥99.9%)

Types: Bare copper / Tin-plated copper (Sn coating: 0.5–1.0μm)

Standard Dimensions (W×T, mm):
9×0.8 | 16×0.8 | 20×1 | 24×1 | 32×1 | 40×1 | 50×1 | 63×1 | 80×1 | 100×1

Lamination Layers: 2–12 layers

Automotive HV Battery Applications:

Foil thickness: 0.25mm ±0.02

Surface finish: Sn0.5–1.0μm (per LV 312-2)

Insulation Parameters

Materials:

Specialty PVC (Polyvinyl Chloride)

TPE (Thermoplastic Elastomer, LSZH/Low Smoke Zero Halogen compliant)

Color Coding: Black (RAL 9005) / Orange (RAL 2004)

Automotive Applications:

Base insulation: TPE (thickness: 0.15mm)

Fire-resistant variant: TPE + Mica-reinforced micatape (UL94 V-0)

Production Standards

Global Certification:

UL758 (Appliance Wiring Material Standard)

GB/T 5023-2008 (Insulated Cable Standard)

Automotive Compliance:

LV 214 (Conductor Requirements)

ISO 6722-1 (Temperature Class 125℃)

Current-Carrying Capacity

Skin Effect Mitigation: Multilayer flat conductor configuration reduces AC resistance by 30–40% vs. round cables.

Current Density:

Flexible BusBar: 12–15 A/mm² (continuous @ 85°C ambient)

Round Cable: ≤8 A/mm² (equivalent cross-section)

Space Efficiency:

25% smaller cross-sectional area required vs. conventional cables

18–22% weight reduction per unit current capacity

Type of the Flexible Connection of the Busbar

Product Advantages

1, High Flexibility

The flexible busbar can be bent and twisted at any angle according to the actual installation space, significantly enhancing installation flexibility. It is particularly suitable for equipment and systems with compact spaces and complex wiring.

2, Low Resistance and High Current-Carrying Capacity

The multi-layer metal foil structure of the Multilayer Copper Foils Flexible BusBars ensures even current distribution, effectively reducing resistance and improving current-carrying capacity. This makes it ideal for high-power equipment requiring efficient electrical transmission.

3, Excellent Shock Resistance

During operation, the flexible busbar effectively absorbs and cushions stresses caused by vibration and impact, preventing fractures or damage at connection points due to stress concentration. This enhances system reliability and stability.

4, Easy Installation

Compared to traditional rigid busbars, the Copper Flexible Busbar offers a simpler and faster installation process, reducing both installation time and labor costs. It also minimizes failure risks caused by improper installation.

5, Long Service Life

With excellent corrosion resistance and shock resistance, the flexible copper busbar maintains stable performance even in harsh environments. This extends equipment lifespan and lowers maintenance costs.

Application

1, Power Systems and Power Transmission & Distribution Equipment

Power Plants and Substations：

Multilayer Copper Foils Flexible BusBar is used for connections between transformers, reactors, circuit breakers, and other equipment. Flexible busbars can alleviate stresses caused by vibrations and thermal expansion/contraction during equipment operation, preventing fractures or poor contact due to mechanical stress in rigid connections.

High and Low Voltage Switchgear：

In dense power distribution systems, Automotive Copper Busbar allows for flexible layout, optimizing space utilization while reducing the risk of connection failures caused by vibrations or installation errors.

2, Industrial Equipment and Machinery Manufacturing

Electric Motors and Generators:

Connect the motor stator to external circuits, accommodating vibrations and minor displacements during motor operation to reduce wire fatigue and damage.

Automated Production Lines:

Serve as flexible conductive components for power or signal transmission in machinery with frequent movement or vibrations (e.g., robots, conveyor equipment), enhancing system reliability.

Heavy Machinery and Engineering Equipment:

BusBar Flexible is applied in mining machinery, construction machinery, etc., to withstand severe operating conditions such as vibrations, impacts, and temperature changes, ensuring stable conductive connections.

3, New Energy and Green Energy Sectors

Wind Power Generation:

Tin-plated copper Bus Bar is used for connections between generators and converters, as well as converters and switchgear in wind turbine nacelles. They adapt to high-frequency vibrations and slight deformations of the tower during operation, reducing maintenance costs.

Photovoltaic and Energy Storage Systems:

In photovoltaic inverters and energy storage battery packs (e.g., lithium-ion batteries, fuel cells), Copper Flexible Busbar buffer the expansion stress during battery charging/discharging, extending system lifespan. They also facilitate modular equipment assembly and maintenance.

Hydrogen Equipment:

Used for connections in fuel cell stacks, meeting flexible conductive needs in compact spaces, and adapting to temperature changes during stack operation.

4, Transportation and Mobile Equipment

Electric Vehicles (Including New Energy Vehicles):

Connect battery packs to motors, electric control systems, and on-board charging equipment (OBC). They withstand vibrations, bumps, and temperature fluctuations during vehicle operation, combining lightweight design with high electrical conductivity.

Rail Transit:

Multilayer Copper Foils Flexible BusBar is applied in traction converters and auxiliary power systems of subways and high-speed trains, reducing connection failures caused by vehicle vibrations and track irregularities to enhance safety.

Marine and Offshore Engineering:

Used in ship generators, propulsion motors, and power distribution systems to resist mechanical stress from seawater corrosion and hull swaying, meeting high-reliability requirements.

PRECAUTIONS FOR USE

Avoid Excessive Bending During Installation:

Although flexible busbars have good flexibility, excessive bending may still cause internal foil sheets to break, affecting conductivity and service life. During installation, strictly follow the product manual to ensure the bending radius is not smaller than the specified value.

Regular Inspection and Maintenance:

Periodically check for loose connections, corrosion, or oxidation on the surface of the Flexible Copper BusBar. Address any issues promptly to ensure normal operation.

Select Appropriate Specifications and Models

Choose Multilayer Bus Bar with suitable specifications based on parameters such as current, voltage, and ambient temperature in the actual application scenario to ensure their performance meets practical requirements.