Multi-Layer Copper Foil Bus Bar For Electricity System
Products Description
Multi-Layer Copper Foil Bus Bar for Electricity Systems are flexible connectors formed by diffusion soldering multiple layers of thin copper foil to create a single conductor under high temperature and pressure. Their core structure consists of the following parts:
Conductive body: Multi-layer precision-cut copper foil stacked structure
Soldering area: Both ends are diffusion soldered to form a rigid connection end
Transition area: The middle is a flexible stacked structure with excellent bending performance
Optional treatments: Surface can be tin-plated, silver-plated, or insulated.
Depending on the application size, small-sized products are mainly used for internal connections in new energy vehicle battery modules, while large-sized products are widely used in power electrical equipment and industrial power distribution systems.
Material Advantages: Peak Electrical Performance of High-Purity Red Copper
T2/C11000 Grade Electrolytic Copper: Copper content ≥ 99.9%. Extremely high purity ensures excellent workability, preventing fatigue cracking even after repeated bending.
Surface Treatment Options:
Overall Tin Plating: Enhances resistance to sulfidation and extends service life in harsh industrial environments.
Silver Plating on Contact Surfaces: Further reduces temperature rise under high-frequency, ultra-high-current conditions, improving contact reliability.
Environmental Compliance: All materials comply with RoHS and REACH international environmental standards, supporting green energy projects for Copper foil flexible bus bar.
Manufacturing Advantages: Flexible Production and Rapid Response
Full Specification Coverage
We have a complete production line ranging from experimental small-batch prototyping to industrial-scale mass production. Whether it's a few centimeters of micro-connectors in new energy vehicle battery packs or large flexible connections several meters long on power transformers, we can provide manufacturing services to the same high standards.
Rapid Mold Development
For customized needs, we adopt modular mold design, significantly shortening the prototyping cycle of new Laminated Copper Electrical Shunts and helping customers seize the R&D time window.
Strict Traceability System
Each batch of Tin Plating Copper Laminated Busbar has a unique traceability code, covering raw material certificates, welding furnace records, quality inspection reports, etc., meeting the stringent requirements of automotive and power industries for supply chain transparency.
Detailed Demonstration – A Visual Presentation of Engineering Quality
| End Welding Zone Compactness | Under a metallographic microscope, the interfaces of multiple copper foil layers within the welding zone are completely fused, with no original interlayer boundaries, forming a uniform copper grain structure, indistinguishable from solid copper. There are no voids or oxide inclusions, ensuring extremely low and stable contact resistance. |
| Flexible Zone Layering Uniformity | The copper foil layers within the flexible zone are neatly arranged, without adhesion or misalignment, and the interlayer gaps are uniform. The edges are precisely trimmed, with no burrs or copper shavings remaining, eliminating the risk of interlayer short circuits. |
| Gradual Transition Zone Design | A gradual thickness transition is used from the welding zone to the flexible zone, resulting in uniform stress distribution. Bending fatigue tests show that fatigue cracks preferentially occur in the flexible zone rather than the transition zone, verifying the rationality of the transition design. |
| End Machining Accuracy | The mounting hole position tolerance is controlled within ±0.1mm, and the inner wall of the hole is smooth and burr-free. The flatness of the terminal is ≤0.1mm to ensure a tight fit with the equipment terminals and uniform contact pressure for Copper Laminated Flexible Shunts. |
contact us
If your Multi-Layer Bending Power Electrical Busbar has higher requirements for conductivity, structural adaptability, and long-term reliability, we can provide customized engineering solutions based on actual working conditions to help you achieve a better balance between performance and cost at the system level.
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