Copper foil soft connection Electrical power copper foil soft connection

When placing an order, please specify the following values:
Length (L)x Width (W)x Thickness (T)

Product shape and hole type
Aperture (d)
Single piece thickness (regular 0.10mm)

Structure and Application Copper foil soft connection is made up of multiple pieces of T2 purple copper foil stacked and welded to both ends. Drilling can be carried out according to customer requirements. Molecular diffusion welding is a precision welding technology that promotes mutual diffusion and bonding between atoms of a workpiece under high temperature and pressure conditions. A high-strength joint is formed while maintaining no visible deformation of the workpiece.
Therefore, copper foil soft connection is an excellent electrical conductor and is usually used in related industries such as new energy vehicles, wind power generation, photovoltaic energy storage, electric locomotives, and complete transmission and distribution.
Customized production can be customized based on customer drawings/samples and provided systematic service support

product Overview

Copper foil soft connection is an indispensable flexible conductive component in modern electrical power systems. It is specially designed to solve various challenges faced by traditional hard buses in installation and operation, such as displacement, vibration, thermal expansion and cold contraction between equipment, and irregular connection requirements, etc. We focus on providing high-quality copper foil soft connection products, especially in the electrical and power field, where they are a key link in ensuring efficient, safe and stable current transmission. The product is made up of multiple pieces of high-purity T2 purple copper foil, with a copper content of more than 99.95%, ensuring excellent electrical conductivity and reliability 。The two ends are tightly fused through an advanced pressure bonding process (also known as molecular diffusion welding) to form a strong and low-resistance connection terminal, ensuring high efficiency and reliability of current transmission. 。

Core technology: high-purity copper foil and precision pressure welding, optimized for power applications

In terms of design and manufacturing, this product fully considers the strict requirements of the electrical and power industry for conduction efficiency, safety and long-term stability, and mainly relies on the following core technologies:

1. High-purity T2 purple copper foil substrate: We choose T2 copper foil as the basic material, with a copper content of not less than 99.95% 。This high-purity copper material has excellent electrical conductivity (high conductivity) and thermal conductivity, which can effectively reduce resistance, reduce energy losses during power transmission (such as Joule heat), and help quickly dissipate heat generated during operation., thereby improving system efficiency and extending equipment life.
2. Molecular diffusion welding (pressure welding) process: The connection areas at both ends of the soft connection body adopt a special pressure welding process 。Pressure welding is an advanced welding technology that promotes diffusion and mutual penetration and integration between copper foil molecules through high temperature and high pressure 。The electrical contact surface formed by it is seamless and dense, with extremely low contact resistance, avoiding the problems of virtual welding, oxide layer and stress concentration that may occur in traditional welding, thereby significantly improving the mechanical strength and electrical reliability of the connection. This is particularly critical in the transmission of large currents in the power system.
3. Multi-layer copper foil laminated structure: The product is made up of multiple thin copper foils stacked together This structure gives the soft connection excellent flexibility. In the connection of power equipment, it can effectively absorb and compensate for vibration, displacement, thermal expansion and contraction caused by equipment operation, foundation settlement or environmental temperature changes, effectively avoid the risk of fracture caused by stress concentration in hard bus connection, and ensure the power system. Long-term stable operation.

Technical data and customization options

We offer a variety of technical specifications and highly customized options to meet the needs of complex applications in the electrical and power sector:

• host material: T2 purple copper foil, copper content ≥99.95% 。
• individual thickness: Provide multiple options such as 0.03mm, 0.05mm, 0.10mm (regular), 0.20mm, 0.30mm, 0.40mm, 0.50mm 。Through the combination of copper foils with different thicknesses, the current carrying capacity, flexibility and overall thickness of the soft connection can be accurately controlled.
• surface treatment: In order to adapt to different power environments and improve performance, we provide a variety of surface treatment methods ：
  • bare copper: Maintain the original excellent electrical conductivity of copper materials and are suitable for dry or indoor environments.
  • tinned: Enhance oxidation resistance and improve the stability of contact resistance. It is especially suitable for humid, dusty or slightly corrosive power environments.
  • nickel plating: Provides excellent wear and corrosion resistance, suitable for use in high temperature or more severe chemical corrosion environments.
  • silver-plated: Provides extremely low contact resistance to achieve optimal conductivity, suitable for power electronic equipment with extremely high requirements for conduction efficiency and signal integrity.
  • Apply nickel sheet/apply silver sheet: Further optimize the conductivity and protective performance of the connection terminal.
• cross-sectional area: Product cross-sectional areas range from 10mm² to 5000mm² , can meet the needs of various low voltage, medium voltage and even high voltage and large current transmission and distribution systems.
• Geometric size and terminal design: We fully support non-standard customization 。

Reflecting product advantages in the field of electrical and power

• increase the power transfer efficiency: High-purity copper and low-resistance press-welded connections minimize energy losses in current transmission and improve the overall efficiency of the power system.
• Enhance system reliability and security: The flexible structure effectively absorbs equipment vibration and displacement and avoids hard connections from breaking due to stress concentration, thereby reducing the risk of electrical faults and ensuring the safe and stable operation of the power system.
• extend equipment life: By reducing vibration transmission and heat accumulation, it effectively reduces mechanical and thermal stress on connected equipment (such as switchgear, transformers, busbars, etc.) and indirectly extends its service life.
• Adapt to complex installation environments: Its flexibility allows it to adapt to various irregular connection angles and space limitations during installation, greatly simplifying the difficulty of on-site construction and shortening the installation time.
• Excellent environmental resistance: Through optional surface treatment (such as tin plating, nickel plating, etc.), the product can effectively resist the erosion of copper materials in harsh environments such as moisture, oxidation, and salt spray to ensure long-term stable operation.
• high current carrying capacity: The large cross-sectional area design combined with excellent electrical conductivity can safely carry large currents and meet the high power transmission needs of modern power systems.
• customized solutions: For the diverse connection needs in the power system, we provide fully customized services to ensure that the product fits perfectly with your specific project.

main application fields

Due to its excellent performance and reliability, electrical power copper foil soft connections are widely used in critical power infrastructure and equipment that require extremely high electrical connections:

• Complete power transmission and distribution system: In high and low voltage switchgear, distribution boxes, substations, and bus duct systems, it serves as a flexible connection between main circuit buses, circuit breakers, and isolating switches to compensate for installation errors and operating vibration 。
• transformer connection: As a flexible connection between a large power transformer and external lines (such as bus bridges and cables), it absorbs vibration and thermal expansion and cold contraction during operation of the transformer.
• Generator connected to motor: In generating sets and large motors, connect the generator outlet terminal, motor junction box and external cables or buses to cope with vibration during equipment startup and operation.
• Power electrolysis and electroplating equipment: In electrolytic cells and electroplating equipment that need to transmit large current, it serves as a flexible connection between high-current bus bars and electrodes.
• new energy power generation: In new energy fields such as wind power generation and photovoltaic power generation, connect key equipment such as generators, inverters, and junction boxes, especially suitable for outdoor and vibration environments. 。
• Electric locomotives and rail transportation: Used in the conductive and grounding systems of electrified railway locomotives and the traction power supply system of urban rail transit to cope with complex operating environments and high current shocks 。
• Industrial furnaces, heating equipment: Used as a high-current conductor connection in industrial electric furnaces and heating equipment to cope with high temperatures and mechanical vibration.
• UPS power supply, data center: Ensure the stability and safety of power transmission in uninterruptible power supply (UPS) systems, data center power distribution cabinets and battery pack connections.