Flexible Copper Foil Connection
Products Description
Flexible copper foil connection bonding is a flexible conductive component composed of multiple layers of high-purity electrolytic copper foil. Stable connection zones are formed at both ends through pressure welding, diffusion welding, or integral pressing, while a highly flexible, freely bendable zone is maintained in the middle.
Compared to traditional copper busbars or braided wires, its structural features are:
The conductive path involves multi-layered contact, rather than a single linear conductor.
The stress distribution is a flexible, integrated buffer, rather than a concentrated stress point.
It can meet the combined requirements of high current, vibration resistance, and displacement compensation within a limited space.
Typical Application Logic of Products of Different Sizes
1. Short-Size Copper Foil Flexible Connections (Mainly for New Energy Applications)
Short and small flexible copper foil connections are typically used in:
New energy vehicle power battery modules/packs
Internal connections within energy storage battery modules
Electrical connections between BMS and power units
Their core functions are:
Absorbing micro-displacements caused by cell expansion and casing deformation
Reducing connection fatigue caused by vibration and thermal cycling
Improving the safety redundancy of the battery system during long-term operation
2. Large-Size Copper Foil Flexible Connections (Mainly for Power Appliances)
Medium and large-size Flexible Tinned Copper Busbar for Distributions are more commonly used in:
Transformers, reactors, switchgear
High-power inverters, rectifier equipment
Industrial power supplies and power control systems
In these scenarios, flexible copper foil connections mainly undertake:
Stable transmission of high current
Thermal expansion compensation
Reducing equipment operating noise and mechanical stress
Detailed Showcase: A Quality Declaration, Excellence Revealed in the Details
Weld Details
The weld width is uniform, the transition is smooth, and there are no spatters, pores, or cracks. Under a metallographic microscope, a dense metallurgical bonding zone can be seen between the layers.
Foil Spreading Area
The foil layers are neatly stacked, without crossing or contamination, presenting an industrial aesthetic. Each foil sheet is freely spread, ensuring uniform current distribution and effective stress dispersion.
Terminal Interface
The contact surface is as smooth as a mirror, without any burrs or scratches. The plating is uniform and dense, with a pure colour, ensuring long-term oxidation resistance and low contact resistance.
R-Angle Transition
The transition area from the foil bundle to the terminal adopts a smooth R-angle design, effectively avoiding stress concentration. This is a key design detail that determines the product's fatigue life.
Multilayer Composite Structure: Unity of Function and Form
A typical structure for C11000 Copper Laminated Flexible Busbars consists of an integrated flexible segment and a rigid end.
Flexible Segment: Precisely stacked from dozens to hundreds of layers of ultra-thin copper foil (thickness as low as 0.05mm). This multilayer structure not only provides axial (tension/compression) and lateral (oscillation) flexibility, but more importantly, it distributes large currents across each copper foil layer for parallel conduction, significantly reducing the skin effect and optimising impedance and temperature rise under high-frequency or alternating current conditions.
Rigid End: The flexible segment is bonded at both ends under ultra-high pressure and temperature to form a robust, solid metal bond. This end can be machined into bolt holes, weld surfaces, or integrated with other connectors as needed. The transition from flexible to rigid is carefully designed and stress-simulated to avoid localised stress concentrations.
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