Flexible Copper Foil Busbar For New Energy Batteries
Products Description
Flexible Copper Foil Busbar for New Energy Batteries are constructed from multiple layers of high-purity electrolytic copper foil, laminated, surface-treated, and insulated. They enable high current transmission, low internal resistance loss, and possess significant bending and structural buffering capabilities.
Their core value lies in:
Replacing traditional rigid busbars, adapting to complex wiring scenarios;
Absorbing thermal expansion and mechanical vibration, extending system lifespan;
Being lighter, thinner, and more flexible, helping battery packs improve energy density and structural utilisation;
Supporting diverse structural designs, easily matching different battery module layouts.
Flexible copper foil busbars have become an indispensable key connection component in various new energy battery applications.
Core Functions: Meeting the core needs of new energy battery systems
High-efficiency Power Transmission
High-purity copper foil conductors and optimised cross-sectional design ensure stable transmission of high current (10A~2000A), with voltage drop ≤0.05V/m. Power loss is reduced by 15% compared to traditional cables, improving the energy utilisation efficiency of the battery system.
01
Flexible Space Adaptability
Can be bent, folded, and twisted arbitrarily, adapting to complex battery pack layouts and confined spaces. Enables integrated connection of cells, modules, and BMS, reducing wiring redundancy and facilitating lightweight and miniaturised battery pack design.
02
Dynamic Environmental Protection
Vibration-resistant, shock-resistant, and fatigue-resistant design allows for stable operation in dynamic scenarios such as new energy vehicle operation and energy storage device start-up and shutdown, preventing faults such as loose connections and conductor breakage, ensuring continuous system operation.
03
Coordinated Thermal Management
Excellent thermal conductivity and heat dissipation characteristics balance the temperature distribution of battery modules, reducing heat accumulation, delaying cell ageing, improving battery cycle life and safety, and adapting to the needs of high-energy-density battery packs.
04
Safety redundancy protection
Flame-retardant insulation, short-circuit protection, and puncture protection design, combined with thermal runaway protection, provide multiple safety guarantees for the battery system, reduce the risk of fire and explosion, and meet the stringent safety standards of the new energy industry.
05
Manufacturing Process: Precision Control of Microscopic Interfaces
Ultra-thin Copper Foil Preparation
Employing electrolytic copper foil technology, the thickness is precisely controlled within the 0.01-0.05mm range to ensure uniformity.
Interface Engineering
Nanoscale chemical treatment is applied to the Laminated Copper Flexible Connectors surface to optimise the interfacial bonding with active materials.
Flexible Structure Design
Through special folding and lamination processes, the structural stability of the copper foil in a bent state is achieved.
Full-Chain Quality Control
Each batch of Flexible Copper shunts undergoes conductivity testing, bending testing, and interface analysis to ensure performance consistency.
Design Advantages
Collaborative Development Model
We are not just a supplier, but your design partner. Our engineering team will be involved from the early stages of the project, collaborating with you on 3D layout, stress analysis, and thermal management design to ensure a perfect match between the No-Plating Flexible Copper Foil Laminated Connectors and your battery system.
Endless Possibilities for Terminal Forms
Whether it's bolt holes, pins, solder pads, or complex irregular structures, we can achieve one-piece moulding using precision moulds, ensuring a seamless, zero-gap connection with your cells, Flexible Busbar for New Energy Batteries, or connectors.
Intelligent Integrated Design
NTC thermistors can be pre-embedded at designated locations on the Flexible Copper Foil Laminated Connectors with Ferrules, or solder points can be reserved for voltage sampling, achieving integrated connection and data acquisition, providing a precise and reliable data foundation for the BMS (Battery Management System).
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