Flexible Copper Busbar For Resistance Welder
Products Description
Flexible Copper Busbar For Resistance Welders are flexible connectors that utilise multiple layers of ultra-thin copper foil for conductivity. Their ends are typically bonded or diffusion-bonded to form an integral conductive contact surface, while the middle layer retains a flexible structure, thus providing:
High current-carrying capacity
Flexible bending performance
Low resistance connection
Vibration resistance
Thermal expansion compensation
In new energy and industrial power systems, it is not only a conductive component but also a key connection structure for improving system stability, safety, and long-term reliability.
Core Functions and Deep Operating Mechanisms
Dynamic Stress Relief and Vibration Isolation
During high-frequency pressure discharge in resistance welding machines or when electric vehicles travel on complex road conditions, the system generates strong three-dimensional vibrations. The Copper laminated foils connector, through its own layered sliding elasticity, perfectly absorbs these mechanical stresses, preventing loosening of the fixed-end bolts or breakage of ceramic insulation components.
Thermal Expansion Displacement Compensation
Temperature fluctuations caused by heavy-duty power systems and battery charging and discharging processes can lead to micron-level thermal expansion and contraction displacements at various electrical interfaces of the equipment. The flexible structure automatically compensates for this expansion difference, maintaining long-term stable contact pressure.
Low Impedance and Non-destructive Conductivity
By maximising the effective conductive cross-sectional area and eliminating intramolecular impurities, the system temperature rise is extremely low, suppressing the vicious cycle of impedance caused by localised high temperatures.
Detailed Showcase: An Engineering Gaze at Micron-Level Processes
| Gradual Annealing in the Transition Zone | We pay special attention to the "transition zone" between the Flexible Laminated Copper Bus Bar area and the rigid welded end. Through localised induction annealing, the heat-affected zone stress generated during diffusion welding in this area is eliminated, resulting in a smooth, gradient decrease in hardness. This is the core secret to preventing root fracture of the flexible connector. |
| Hole Chamfering and Deburring | All Copper Foil Flexible Busbar For Rail Transit mounting holes undergo secondary precision reaming and chamfering to eliminate microburrs remaining from stamping, ensuring that bolt tightening will not scratch the silver plating layer of the terminals and reduce contact resistance. |
| Zero Dead Angles in Insulation Coverage | For new energy applications, we use polymer insulating heat shrink tubing or epoxy coating to implement a special "umbrella-shaped" or "arc-shaped" covering at the root of the end, preventing the insulation layer from cracking during bending and ensuring high insulation withstand voltage requirements within the battery pack. |
| Surface Protection, Passivation, and Plating | To meet the anti-oxidation requirements of power equipment and welding machines, the entire flexible connector can be passivated, tin-plated, or silver-plated. The coating is uniform and dense, maintaining low resistance and stability at the contact surface even in humid, hot, and oily environments. |
Material Advantages: Performance Traceability from Copper Ingot to Conductor
1. Highly Conductive Copper Foil Substrate
Two substrate systems are selected: T2 copper (Cu ≥ 99.9%) and oxygen-free copper (OFC):
Conductivity: ≥ 100% IACS (International Standard for Annealed Copper), resistivity ≤ 0.01724 Ω·mm²/m;
Elongation: ≥ 35% (soft state), ensuring no grain boundary fracture under repeated bending;
Surface Treatment: Tin plating, nickel plating, or bare copper, with anti-oxidation solutions selected based on the application environment.
2. Interlayer Insulation and Thermal Conductivity Balance
For new energy battery packs, 0.05mm~0.1mm polyimide (PI) film or high-temperature resistant PET is used as interlayer insulation, with a temperature resistance rating of up to 220℃, while maintaining interlayer thermal conductivity efficiency and avoiding localised hot spot accumulation.
Contact us
We not only provide standardised Copper Laminated Flexible Shunts products, but also offer integrated engineering support, from material selection and structural optimisation to mass production, tailored to customers' current design, installation structure, and new energy application scenarios, helping projects achieve more stable and efficient long-term operation.
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