Laminated Flexible Busbar For New Energy Vehicles
Products Description
Laminated Flexible Busbar for New Energy Vehicles employs a multi-layered, ultra-thin copper foil stacked structure, unlike traditional single-unit copper busbars. Their core advantage lies in balancing high conductivity with mechanical flexibility.
The product typically consists of the following components:
Multi-layered high-purity copper foil conductors
Welded compaction area
Flexible compensation area
Surface insulation layer (optional)
Platinum protection structure
Positioning and mounting hole structure
Depending on application requirements, it can be designed as:
Single-end welded structure
Double-end compaction structure
Irregular bending structure
Multi-hole connection structure
Insulation coating structure
Ultra-thin flexible connection structure
Design Advantages
Modular Layers and Thickness
For the same width specification, the current-carrying capacity can be linearly adjusted by adding or removing copper foil layers, thereby eliminating the need for mold redesign. This "building block" design allows small-batch customization and large-scale standard parts to share the same process platform, shortening the prototyping cycle.
3D Bending Pre-forming
The laminated structure can be pre-bent before hot pressing, and after hot pressing, it is shaped into a three-dimensional spatial form (such as Z-shape, U-shape, or stepped shape), directly adapting to the height difference layout inside the battery pack or the multi-layer copper busbar routing in the electrical cabinet, reducing the uncertainty of on-site secondary forming.
Precise Insulation Boundary Control
Through mold design, the insulating film can be precisely terminated at the end root, forming a clear "insulation-conductivity" boundary. Copper Foil Connector avoids overlap area loss due to excessive insulation layer extension or creepage risk due to insufficient insulation.
Integrated Sensing Interface
For the needs of smart battery packs, wiring channels for NTC temperature sensors or voltage sampling lines can be reserved in the insulation layer, upgrading the flexible connection from a "purely conductive component" to an "integrated electrical component," reducing wiring redundancy within the module.
Manufacturing Advantages | Controllable Process Equals Controllable Quality
Closed-loop control of three key diffusion welding parameters,
Welding temperature, pressure, and time are the core determinants of molecular bonding quality. Precise monitoring and feedback adjustment of these three parameters ensures batch-to-batch consistency and eliminates the risk of poor soldering caused by equipment drift.
01
Non-destructive testing system
Solder joints in critical batches undergo internal "check-ups" using an ultrasonic scanning microscope, identifying internal defects such as poor soldering, slag inclusions, and delamination without damaging the Copper Foil Laminated Connectors.
02
Full-process traceability
From the batch number of incoming copper foil, heat treatment records, and welding curve archives to the final test data, all materials are traceable, meeting the quality management requirements of ISO9001, IATF16949, and other systems.
03
Quick mold and fixture changeover system
For batch customization needs, a standardized mold library is established, enabling efficient conversion from drawings to the first piece, shortening the delivery cycle of customized Copper Flexible BusBars for Lithium Battery.
04
Application Advantages: Bridging the Gap Between New Energy and Traditional Power in Multiple Scenarios
1. Refined Application in the New Energy Vehicle (NEV) Sector
In the battery packs of passenger or commercial vehicles, space is often contested on a millimeter-by-millimeter scale.
Small-size flexible connectors, with their high flexibility, navigate between compact modules, even withstanding the "bulging" force caused by cell aging. Flexible Copper Shunts are ideal for interconnecting intelligent BMS, blade batteries, and cylindrical or prismatic modules.
2. Robust Performance in Modern Power and Heavy Electrical Systems
In distribution cabinets, transformers, photovoltaic inverters, and wind power slip ring systems that operate at thousands of amperes:
Large-size flexible connectors replace bulky traditional cables or rigid copper busbars. This not only reduces installation stress within the cabinet but also makes the overall wiring more compact and neat, significantly reducing on-site assembly and subsequent maintenance time.
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We not only offer standardized Copper Foil Laminated Bus bar products, but also provide integrated engineering support solutions tailored to customers' battery pack structures, current paths, spatial layouts, and assembly processes. These solutions range from conductor structure design and flexibility compensation optimization to mass production implementation, helping new energy projects achieve more stable and efficient system connections.
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