Laminated Copper Electrical Shunts
Products Description
Laminated copper electrical shunts are flexible conductive connectors formed by laminating multiple layers of high-conductivity copper foil and then bonding them using processes such as diffusion welding, molecular welding, pressure welding, or brazing. Their structure typically consists of:
Multi-layer copper foil conductors
Welded and compacted end faces
Flexible bending areas
Surface insulation layer (optional)
Platinum conductive terminals
Compared to traditional copper busbars or braided copper strips, laminated copper foil structures offer significant advantages in conductivity efficiency, flexibility, and adaptability to dynamic operating conditions.
Precision Details Showcase: High-Quality Manufacturing
| 100% Fully Dense Fusion Cross-Section | After the diffusion-welded ends are cut open, metallographic microscopy reveals that the original copper foil delamination has completely disappeared, transforming into a continuous, uniform pure copper grain structure, free of any pores, pinholes, cold solder joints, or non-metallic inclusions. |
| Anti-Arc Edge | All exposed edges of the ends and flexible transition sections undergo finely polished rounded corners. The absence of sharp edges effectively prevents localized tip discharge or corona discharge in high-voltage electrical applications, ensuring the system's electromagnetic compatibility (EMC). |
| Optional Interlayer Anti-Adhesion Process | For specific projects requiring ultra-high flexibility, the non-welded sections of the copper foil can undergo micron-level anti-adhesion processing. This allows the copper foil layers to slide freely and smoothly like pages in a book when bent under stress, further reducing the overall structural stiffness coefficient and achieving compact bending at extreme angles. |
| Rigorous electrical and physical performance inspections | Every batch of Copper Laminated Flexible Busbars undergoes rigorous low DC resistance (Micro-ohm) testing, high voltage insulation withstand voltage (Hi-Pot) screening, and tensile strength mechanical testing before leaving the factory. All mass production data is digitally archived, fully complying with high standards of global power engineering traceability. |
Main Functions: Flexible Compensation in Current Paths
High Current Conduction
Multilayer Flexible Copper Bus bar for Switchgear parallel connection provides a low-impedance path, with current-carrying capacity linearly expanding with the number of layers and cross-sectional area, meeting the extreme current requirements of battery pack fast charging or power transformer short circuits.
01
Three-Dimensional Tolerance Absorption
In battery pack module assembly, it absorbs manufacturing tolerances and thermal expansion/contraction displacements between cells, modules, and the casing, avoiding shearing of terminals or tearing of welds caused by rigid connections.
02
Vibration Isolation
During vehicle operation or power equipment operation, Copper laminated foils connector isolates vibration transmission through flexible deformation, protecting battery terminals, ceramic insulators, or circuit breaker terminals from fretting wear.
03
Thermomechanical Stress Buffering
During charging/discharging thermal cycles or power load fluctuations, it compensates for the linear expansion of conductors through elastic expansion and contraction, preventing thermal stress accumulation at fixed ends.
04
Installation Compliance
Pre-bent flexible connections eliminate the need for forced alignment during on-site assembly, reducing assembly stress and the risk of human-caused damage.
05
Manufacturing Advantages: End-to-End Micro-Defect Detection and Customized Flexibility
For electrical connectors, even minute internal defects can be the trigger point for future thermal runaway:
Ultrasonic C-scan Non-destructive Testing: Every batch of diffusion-welded terminals undergoes ultrasonic C-scan imaging inspection. This accurately identifies minute voids, incomplete fusion, or cracks within the weld surface, ensuring an effective weld area ratio far exceeding industry benchmarks and minimizing fluctuations in thermal resistance and contact resistance.
Full-Spectrum Delivery from Millimeter to Hundred-Millimeter Scale: We possess a flexible production line layout, capable of producing short jumpers with cross-sections of only a few square millimeters within battery packs, as well as massive Flexible Laminated Copper Bus Bar with cross-sections of thousands of square millimeters and lengths exceeding meters on power transformers. This ensures consistent high quality across different specifications without requiring changes to core process logic.
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We not only provide standardized Laminated Flexible Copper Busbars products, but also offer integrated engineering support, from conductive structure design and material selection to mass production, tailored to customers' equipment structures, current schemes, and assembly processes. This helps new energy and power projects achieve more stable and reliable long-term operation.
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