Copper Foil Battery Busbar Connector
Products Description
Copper Foil Battery Busbar Connectors are precision components formed by stacking multiple layers of highly redundant ultra-thin electrolytic copper foil and then pressure welding (molecular diffusion welding) or brazing at both ends.
Small connectors (EV Grade): Focused on the series and parallel connection of cells within new energy vehicle battery modules (packs), emphasizing extremely small bending radii within high energy density spaces.
Large connectors (Utility Grade): Used in transformers, electrolytic cells, and high-current switchgear, addressing structural displacement caused by thermal expansion and contraction in large power equipment and ensuring connection stability when carrying currents up to thousands of amperes.
Design Advantages
Parametric Flexible Area Design
The length, width, stack thickness, and corrugation geometry of the flexible area can all be parametrically adjusted, establishing a quantitative relationship with cell expansion stroke, installation space constraints, and current-carrying capacity requirements. This enables the achievement of an optimal solution that meets performance demands from the design stage.
Terminal Structure Diversity
The end-welding area can integrate: ① Through holes (for bolted connections); ② Threaded inserts (copper or stainless steel, for repeated disassembly and assembly); ③ Welded lugs (for laser welding or ultrasonic welding to connect cell electrodes); ④ Multi-branch structures (one-to-two, one-to-three, for parallel current sharing).
Integrated Sensing Function
Embedding NTC temperature sensors or current sampling resistors in the stacked structure upgrades the connector's temperature and current monitoring functions, supporting the intelligent management requirements of the BMS.
Lightweight Potential
Compared to solid copper busbars with the same current-carrying capacity, the actual density of the Copper Foil Flexible Busbar Connectors with Insulation is reduced by 10-20% due to interlayer gaps and flexible area corrugations, making a marginal contribution to the overall vehicle lightweight design.
Technical Features and Process Flow
1. Precision Stamping and Lamination
Utilizing a high-precision automated lamination machine, hundreds of copper foil layers are edge-aligned with errors controlled to the micron level.
2. Vacuum/Atmosphere Protected Soldering
The entire soldering process is conducted in a controlled environment to prevent copper foil oxidation at high temperatures, ensuring the finished product has a natural copper luster without the need for excessive acid pickling.
3. Diverse Surface Treatments
Tin/Silver Plating: Enhances the oxidation resistance of the joints, preventing electrochemical corrosion in humid or salt spray environments.
Nickel Plating: Copper Foil Flexible Busbar with Insulated Tube. Provides a more stable protective layer for high-temperature environments.
Key Functions and Application Advantages
Electric Vehicle Battery Packs (EV Battery Packs)
Within the compact battery pack, flexible copper foil connectors easily bypass structural components to connect irregularly distributed battery modules. Their lightweight characteristics are crucial for improving the overall vehicle range.
Electrical Appliances and Distribution Systems
Large transformers generate continuous micro-vibrations during operation. Press Welding Foil Busbars can break the vibration transmission chain, protecting vulnerable components such as ceramic insulators from mechanical stress damage.
Energy Storage Systems (ESS)
In large-scale energy storage cabinets, New Energy Battery Copper Foil Flexible Connectors provide extremely high installation tolerance, significantly reducing on-site assembly time and costs.
contact us
If you are evaluating critical conductive connection solutions in battery systems or power equipment, we can provide structural optimization and customization support based on specific operating conditions. You are welcome to submit engineering parameters to obtain a customized technical solution for Laminated Flexible Busbar for New Energy Vehicles.
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