Multilayer Copper Foils Flexible BusBars Industry Knowledge

Multilayer Copper Foils Flexible BusBar. It uses high-quality 0.05 to 0.3 mm thick copper foil as the base material (some cases also use special specifications such as 0.5 mm thick copper foil, depending on actual needs), and the laminated parts of the copper foil are tightly pressed together. The two ends are formed into a hard connection part through the diffusion welding process, and the middle part is a soft connection part, thus creating a flexible copper foil diffusion solder flexible connection busbar structure. This unique structural design has good conductivity and flexibility and can meet the conductive connection requirements in a variety of complex scenarios.

(I) Principle
Diffusion welding is a welding process that causes the atoms on the contact surface of the copper foil to diffuse with each other under high temperature and pressure, thereby forming a metallurgical bond. In the production of Multilayer Copper Foils Flexible BusBar, a polymer diffusion welding machine is used to generate high temperature using a large current to split the copper foil and melt it for pressure welding. At high temperature, copper atoms obtain enough energy to overcome the resistance between atoms, migrate from the high concentration area to the low concentration area, form bonds between atoms at the interface, and achieve a firm connection between the copper foils.

(II) Process
Material selection: Select high-quality copper materials such as T2 copper strips with a copper content of more than 99.9% to ensure that the copper foil has good conductivity and ductility. At the same time, copper strips are divided into soft and hard states according to their states, and can be selected according to different production and installation requirements to adapt to different application scenarios of Copper Laminated Foil Busbars.

Stacking preparation: Stack the copper foil according to the number of layers and sizes required by the design to ensure that the stack is neat and flat, and prepare for subsequent welding. This is one of the key steps in making high-quality Copper Laminated Foil Busbars.

Welding: Place the stacked copper foil on the workbench of the polymer diffusion welding machine, and set appropriate welding parameters, such as adjusting the welding time, pressure and temperature, to achieve diffusion welding at both ends of the copper foil under high temperature and high pressure. The welding time usually ranges from a few seconds to tens of seconds depending on the thickness and number of layers of the copper foil. The pressure is generally between tens and hundreds of kilopascals, and the temperature needs to reach above the recrystallization temperature of copper, generally around 800℃ - 1000℃ (the specific value will vary slightly depending on the equipment and materials). Accurate welding parameter control is crucial to ensure the welding quality of the Flexible Copper Busbar Laminated Foils Connector.

Post-processing: After welding, the finished product is passivated to remove impurities such as the oxide layer on the surface. At the same time, the burrs, stains, corrosion, bumps, scratches, etc. on the surface and surrounding areas are processed. The overlapping surfaces can also be drilled according to needs, the soft connection parts can be covered with insulating sleeves as a whole or partially, and the products can be tinned, silver-plated or nickel-plated as a whole or partially to meet different use environments and performance requirements, and further improve the applicability of Flexible Copper Busbar Laminated Foils Connectors.

High conductivity: Due to the use of high-purity copper foil as raw material, and the diffusion welding process to form a good metallurgical bond between copper foils, the resistance value is small, and it can efficiently conduct current. The conductivity is high and can meet the needs of large current transmission. This feature makes the Flexible Copper Busbar Laminated Foils Connector stand out among many conductive connection products.

Good heat dissipation: Copper itself has excellent thermal conductivity. The Copper Foil Bus Bar can play a role in auxiliary heat dissipation, quickly dissipating the heat generated during the operation of the equipment, which helps to maintain the normal operating temperature of the equipment and improve the stability and service life of the equipment.

Flexibility and earthquake resistance: The flexible connection part in the middle can be bent and twisted arbitrarily, which can absorb the noise and vibration generated by the operation of high-current electrical equipment, avoid operating accidents caused by earthquakes, displacements, etc. in the surrounding environment, and make the conductive connection between high-current equipment more convenient, reliable and safe, protect the related equipment from external forces, and give full play to the unique advantages of the Copper Foil Bus Bar.

Installation convenience: Its swingable and rotatable characteristics can meet the assembly requirements of different angles, improve the installation speed and practicality of the product, facilitate installation and connection in various complex space layouts, and greatly improve the application flexibility of the Copper Foil Resistance Diffusion Soldering Flexible Connection.

Corrosion Resistance: Through surface treatment processes such as tin plating, silver plating, and nickel plating, the corrosion resistance of the Copper Foil Resistance Diffusion Soldering Flexible Connection can be effectively improved, so that it can work stably in harsh environments such as humidity, acid and alkali.