Copper Foils Connector For Switchgear
Products Description
Copper Foils Connector for Switchgear are flexible conductive connectors, typically composed of multiple layers of thin-gauge copper foil precisely laminated together. Stable conductive terminal areas are formed at both ends through pressure welding, diffusion welding, or integral crimping.
Their core structural features include:
Multi-layered structure: The copper foil layers are tightly bonded, forming a low-contact-resistance conductive channel.
Flexibility and bendability: Absorbs displacement, thermal expansion and contraction, and vibration during equipment operation.
Integrated end treatment: High connection strength, suitable for bolt or clamp mounting.
Optional surface treatments: Tin plating, silver plating, or anti-oxidation treatment to adapt to different application environments.
This structure significantly reduces the risk of failure due to mechanical stress or temperature differences while maintaining high current carrying capacity.
Material Advantages: Ensuring Reliability of Power Transmission from the Source
High-Purity Core Conductive Materials
Using T2/T3 oxygen-free copper foil (or customized Cu-ETP electrolytic copper foil): Welding Multilayer Flexible Bus Bar Connector purity ≥99.99%, conductivity ≥58MS/m, compared to ordinary copper, conductivity is improved by 12%, and current transmission loss is reduced by 15%; copper foil thickness is controlled at 0.05~0.2mm, thickness uniformity error ≤±0.005mm, ensuring uniform current distribution after lamination and avoiding localized heating; oxygen-free copper has an oxygen content ≤0.003%, excellent mechanical properties, tensile strength ≥205MPa, and bending fatigue life ≥10000 cycles without breakage. 2. High-Performance Auxiliary Materials
Insulation Material: The silicone rubber insulation layer has a temperature resistance range of -50℃ to +180℃, excellent aging resistance and arc resistance, meets the UL 94 V0 flame retardant standard, and does not crack or peel off under long-term high-temperature environments;
Welding Material: Silver-based brazing filler metal (silver content ≥60%) is used, with a low melting point, good fluidity, high welding strength, and the conductivity of the joint is close to that of the base material, eliminating the risk of false soldering or cold soldering;
Elastic Material: The terminal elastic components are made of beryllium bronze, with excellent elastic recovery performance and a fatigue life ≥100,000 cycles, ensuring stable contact pressure even after long-term use.
Application Advantages
Medium and High Voltage Switchgear
Connecting circuit breakers, disconnectors, and busbars, its flexibility perfectly absorbs the electrodynamic shocks of opening and closing, making it a core component ensuring safe operation.
Generator Outlet Circuit Breakers
Flexible Copper Foil Busbar provides reliable electrical connections and mechanical buffering in harsh environments subjected to huge short-circuit currents and generator vibrations.
Power Transformers and Reactors
Used to connect winding leads and bushings, effectively compensating for thermal expansion and contraction and preventing stress-induced winding insulation damage.
Heavy Industrial Equipment such as Electric Furnaces and Electrolytic Units
Laminated Cu Busbar Multi-Layer Welding Flexible Copper Bus Bars superior fatigue resistance ensures continuous production under continuous vibration and thermal cycling conditions.
The devil is in the details: A profound presentation of professional value
Double-arched elastic structure
Each C11000 Copper Laminated Flexible Busbar is not flat, but rather features a precisely pre-designed arch. Once installed and secured, this structure generates a continuous, adaptive elastic feedback force, compensating for stress relaxation caused by material creep and thermal cycling. This is the core secret to maintaining long-term contact pressure.
Differentiated thickness design
Along the connector's length, the Flexible Copper Busbar Customized for Ingot Furnace thickness can be differentiated based on current density distribution and heat dissipation requirements. Thicker at the end contact area to reduce resistance, and moderately thinned in the central flexible area to enhance flexibility, achieving a precise balance between performance and cost.
Anti-electrochemical corrosion interface
When connecting dissimilar metals (such as copper and aluminum), we provide dedicated connectors or intermediate gaskets with transition plating, effectively blocking electrochemical corrosion pathways and solving the long-term reliability challenges of dissimilar metal connections.
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