Flexible Laminated Flat Copper Busbar
Products Description
Flexible Laminated Flat Copper Busbars are composed of multiple layers of ultra-thin copper foil stacked in a specific direction. The ends are bonded together using molecular diffusion welding, high-voltage welding, or brazing processes to form a single conductive terminal, while the middle region maintains a flexible structure.
This design combines:
The high current-carrying capacity of copper busbars
The flexibility of copper braided strips
The heat dissipation advantages of laminated structures
customised installation adaptability
Therefore, it has become an increasingly important electrical connection solution in new energy high-voltage systems.
Design Advantages: From "Usable" to "Optimal"
Precise Calculation of Flexible Segment Length
Based on the maximum relative displacement between two connection points (vibration amplitude + thermal expansion difference) and the allowable bending radius, we calculate the most economical flexible segment length.
Asymmetrical End Design
Depending on the equipment space, we can design one end as a straight terminal and the other as an L-shaped or Z-shaped terminal, avoiding interference between the flexible connection and surrounding components.
Multi-Segment Flexible Connection
A single busbar can be designed with a "rigid-flexible-rigid-flexible-rigid" structure. The rigid section in the middle is used to fix or install sensors, while the flexible sections at both ends absorb displacements in different directions.
Layer Spacing Control
For ultra-high currents (>2000A), double or multi-layer laminated flexible connections can be used in parallel, separated by insulating gaskets, with each layer replaceable independently.
Manufacturing Advantages
Automated Lamination Equipment
Copper Flexible Bus Bars Bending Utilising high-precision laminators, we precisely control the number of layers, pressure, temperature, and lamination time to ensure a tight, delamination-free interface.
01
Integrated Processing Capabilities
We support integrated processing of punching, bending, end crimping, tin plating, and secondary insulation, shortening delivery cycles.
02
Stringent Quality Control System
From copper foil raw materials to finished products, we conduct thickness uniformity testing, peel strength testing, electrical performance verification, and vibration ageing tests, ensuring full batch traceability.
03
Large-Scale Customisation Response
We can quickly meet diverse order demands, from small-section, short-pitch Flexible Copper Busbar for Automotive Power Distributions for battery packs to large-specification, long-pitch products for power appliances, guaranteeing a stable supply for large-scale projects.
04
Main Functions of the Product
| Firstly, stable conduction of ultra-high current | As the core conductive path, relying on the ultra-large conductive cross-sectional area of multi-layer copper foil, Copper Aluminium Composite Laminated Busbar stably carries large currents with low transmission loss and low temperature rise, meeting the power supply needs of high-power equipment such as new energy vehicle battery packs and power transformers. |
| Secondly, thermal expansion and contraction displacement compensation | A core feature, the flexible section in the middle can compensate for the thermal expansion and contraction displacement generated by battery charging and discharging and equipment operation, releasing mechanical stress and completely solving the problems of cracking and loosening of rigid connections. |
| Thirdly, low inductance and high-efficiency transmission | The optimised laminated structure significantly reduces system inductance, reduces high-frequency current transmission loss, improves the power conversion efficiency of equipment such as new energy vehicle inverters and charging piles, and reduces electromagnetic interference. |
| Fourthly, efficient heat dissipation ensures safety | The flat, multi-layered structure provides a large heat dissipation area. Combined with the excellent thermal conductivity of copper foil, it quickly dissipates the heat generated by high currents, avoiding safety hazards caused by localised overheating. |
| Fifthly, it offers anti-oxidation and anti-corrosion protection | The surface coating isolates it from external corrosive media, making the Copper Inverter Laminated Busbar suitable for various complex environments such as indoor factories, outdoor stations, and new energy vehicle cabins, extending product lifespan. |
contact us
Whether you are developing new energy vehicle battery packs, energy storage systems, high-voltage DC contactors, or large-scale power equipment, our engineering team can provide a one-stop Copper Foil Laminated Flexible Bus Bars solution based on current requirements, installation space, and application conditions, from structural design and material selection to mass production, helping your projects achieve higher reliability and more stable mass production delivery.
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