Aluminum Foil Laminated Connectors
Products Description
Aluminum foil laminated connectors are electrical connection components formed by stacking multiple layers of aluminum foil and then insulating and pressing them together. Compared to traditional single-piece aluminum busbars or cable connections, their essential characteristics are:
Distributing the current path through a "multi-layer parallel" method
Improving overall mechanical stability through the laminated structure
Achieving efficient and controllable current transmission within a limited space
This product is not a simple conductor replacement, but a functional connector that allows for deep involvement in the system design phase, and can be customized according to equipment structure, current flow, and installation conditions.
Core Product Properties and Features
| Lightweight and Thin Design | Utilizing high-purity aluminum foil as the core conductive material, it reduces weight by more than 35% compared to traditional copper connectors. The thickness can be achieved in a thin design of 0.1~1.0mm, with a unit area weight only 1/3 that of copper connectors, significantly reducing the overall weight of equipment and meeting the needs of lightweight product development. |
| Ultra-Flexible and Fatigue-Resistant Properties | The multi-layer laminated composite structure combined with the thin aluminum foil substrate allows for small-radius bending (minimum bending radius ≤0.5mm), vibration resistance of 5~2000Hz, and a repeated bending life of ≥15000 cycles without breakage or interlayer peeling, adapting to complex installation paths and vibrating working environments. |
| Low-resistance, high-efficiency conductivity | High-purity aluminum foil substrate combined with interface optimization technology achieves conductivity close to the theoretical value of pure aluminum, resulting in extremely low contact resistance. It can stably conduct current from 10 to 500A, with an operating temperature rise of ≤15K. Power transmission loss is reduced by 25% compared to traditional 6061 aluminum bus bar, ensuring improved equipment energy efficiency. |
| All-environment weather resistance | The aluminum foil surface undergoes anti-oxidation treatment, combined with a high and low temperature resistant insulation layer, allowing stable operation in a wide temperature range of -55℃ to +125℃. It possesses resistance to moisture, salt spray, and chemical corrosion, making it suitable for various complex indoor and outdoor industrial environments. |
| Precision compatibility | Customization is supported according to device interface size, current rating, and installation method. Various specifications are available, including single-row/multi-row contacts, bare foil/insulated wrapping, and different spacing, adapting to high-density integrated equipment and confined installation spaces, meeting personalized precision connection needs. |
Material Advantages
Conductor: High-purity electrical aluminum foil (1060/1070): We select soft aluminum foil with a purity of over 99.6%. Its excellent conductivity and ductility are the physical basis for achieving high current transmission and lamination. Each batch of aluminum foil undergoes rigorous composition and mechanical property testing.
Key "Adhesive": Special polymer composite film: This is the core of our technology. Invertor Applied Aluminum Busbar is not ordinary glue, but a special engineering film that combines high insulation strength, excellent thermal conductivity, and long-term thermal stability. Under high temperature and pressure, it bonds the aluminum foil together at the molecular level, simultaneously undertaking the dual mission of interlayer insulation and overall structural reinforcement.
Design Advantages
"Hybrid Material" Design Concept: Our design begins by viewing the Aluminium Flat Bar Plate as a "system," not a single material. We precisely calculate the number of aluminum foil layers, thickness, and composite film formulation to match your specific current carrying capacity, temperature rise, and mechanical performance requirements, achieving true "on-demand customization."
Stress Dispersion Topology Optimization: The transition area between the Aluminium Bus Bars for Cell Connection and terminals is a top priority in our design. Through CAE simulation, we optimize its geometry to ensure that current and stress are smoothly transferred from one area to another, avoiding any performance bottlenecks or structural weaknesses.
Products Description
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