Flexible Busbar
Product Series Introduction
Copper Foil Diffusion Welded Flexible Busbar
This product utilizes multiple layers of T2 copper foil bonded together by diffusion welding. The surface can be covered with an insulating layer or a protective plating layer.
Features:
Integrated conductive layer, no mechanical solder joints;
Low resistance ≤ 0.00001Ω, withstand voltage up to 5000VDC;
Current carrying range 100A–2000A;
Excellent flexibility, suitable for high vibration and thermal cycling applications.
Common surface finishes:
Silver plating / Tin plating / Nickel plating / Ultrasonic cleaning
(Plating thickness 3μm–12μm, customizable upon request)
Copper Braided Flexible Connector
Made with T2Y2 copper braid (GB standard) or E-Cu58 copper stranded wire (DIN standard) and crimped terminals, it offers excellent flexibility and stable conductivity.
Terminal Structure:
Uses high-conductivity copper tube or crimped copper lug terminals (Crimped Copper Pipe / Copper Lug Terminals)
Supports single-layer 1.5mm² to 150mm², and custom multi-layer braided structures are also available.
Optional insulation options include PE heat shrink tubing, fibreglass insulation tubing, and more.
Insulation Performance Parameters:
Flame Rating: UL94-V-0
Operating Temperature: -45°C to +150°C
Common Colours: Red, Orange, Blue, Green, Black
Tinned Braided Copper Connector
Tin-plated copper braided wire prevents oxidation and improves weldability. Suitable for long-term operation in humid, high-salt spray, or high-temperature environments.
Features:
Uniform surface coating for enhanced corrosion resistance;
Maintains ≥97% IACS conductivity;
Suitable for connecting new energy battery modules, converters, and distribution busbars.
Copper Braided Wire Roll
Serves as raw material for busbars or the basis for flexible connector components. It can be delivered in rolls for mass production or end assembly.
Mechanical Properties: Hardness 80–110 HV, tensile strength 245–345 MPa. Other copper alloys (such as CuNi and CuSn) can be customized.
Main Technical and Performance Parameters
| Item | Technical Specifications |
| Copper Busbar Resistance | ≤0.00001Ω |
| Load Voltage / Current | 3500VDC–5000VDC / 100A–2000A |
| Base Material | High-purity Red Copper ≥99.99% |
| Surface Treatments | Silver / Tin / Nickel Plating or Diffusion-Soldered Nickel Sheet Protection |
| Assembly Fixtures | USA PEM Stainless Steel Nuts, Studs, Support Pillars, Screws, etc. |
| Insulation Options | PET Paper, PVC Coating, Epoxy Powder, PE Heat Shrink Tubing, PA66 Molded Case |
| Flame Retardant Level | UL94-V-0 |
| Operating Temperature | -45°C to +150°C |
| Free Samples | 1–10 pcs available |
| Lead Time Samples | 10–20 days (including mold making), Orders 7–10 days |
| Production Capacity | 50,000,000 pcs/month |
| Packing | Packed in EPE foam or blister packaging, with outer packaging in cartons/pallets |
| Certifications | ISO9001, IATF16949, RoHS, REACH |
| OEM/ODM | Services are accepted; design drawings are required |
Manufacturing and Quality Assurance
XIAMEN APOLLO boasts a comprehensive copper braided wire and copper foil diffusion bonding production line:
Utilizing automated braiding, ultrasonic cleaning, electroplating, diffusion bonding, and laser welding technologies;
The entire process adheres to the ISO/IATF16949 quality control system.
Key parameters such as resistance, conductivity, pull-out strength, and dielectric strength are 100% tested.
Online CCD testing and a constant temperature welding control system ensure batch consistency.
Through precise craftsmanship and rigorous testing, our products offer exceptional resistance to arcing, vibration, and thermal cycling, ensuring long-term stable operation in complex industrial environments.
Typical Applications
The Flexible Busbar series is widely used in:
New energy electric vehicles and hybrid systems (Film Capacitor Busbar)
Energy storage battery modules and photovoltaic energy storage inverters
Power converters and distribution busbar systems
Rail transit traction and braking systems
Cloud server UPS power supplies and communication base station power supply systems
Industrial inverters and high-power control units
Custom Engineering and Service Support
The XIAMEN APOLLO engineering team can provide:
Copper tape/braided wire structure optimisation and flexibility analysis;
Insulation coating design and thermal stress simulation;
Resistance, current density, and heat dissipation path calculations;
Quick OEM/ODM prototyping and life verification.
Through our integrated production system, we provide comprehensive support from design verification to mass production within a short lead time.
Reasons to Choose XIAMEN APOLLO
Over 30 years of experience in new energy electrical metal manufacturing.
Complete production system: copper braiding - stamping - diffusion bonding - plating - assembly in one integrated system;
Monthly production capacity of over 50 million units, supporting batch delivery to global customers;
Strictly adheres to ISO9001 / IATF16949 / RoHS / REACH;
A trusted supplier for customers worldwide, serving a wide range of industries, including EV, ESS, Rail, and Server.
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