Copper foil soft connection Tinned 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 : Including the shape of the terminal (such as flat plate, drilled hole, etc.) and the layout of the holes. Drilling holes can be drilled in the welding area according to customer requirements

Aperture (d) : Diameter of the bolt hole

Single 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 introduction

Copper foil soft connections are crucial flexible conductive elements in the field of modern electrical connections. They are widely used in applications that require flexible connections, compensate for displacement or absorb vibration. andTin-plated copper foil soft connectionOn the basis of traditional copper foil soft connection, by plating a uniform tin layer on the surface of the copper foil, the oxidation resistance, corrosion resistance and electrical contact properties of the product are greatly improved. It is made up of multiple pieces of high-purity T2 purple copper foil stacked, with a copper content of more than 99.95% , ensuring excellent electrical conductivity. The two ends are closely integrated through advanced pressure welding process (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, supplemented by tin plating process

This product combines multiple key technologies to ensure excellent performance:

1. High-purity T2 purple copper foil: We choose T2 copper foil as the substrate, with a copper content of not less than 99.95% , has excellent electrical conductivity (high electrical conductivity) and thermal conductivity. High-purity copper can effectively reduce resistance, reduce energy loss, and help with heat dissipation.
2. Molecular diffusion welding (pressure welding): The connection areas at both ends of the soft connection body adopt a special pressure welding process 。This technology uses high temperature and high pressure to promote diffusion between copper foil molecules and penetrate into each other and integrate into one body. , forming a seamless and dense electrical contact surface. Compared with traditional brazing or resistance welding, pressure welding avoids the introduction of filler metals and eliminates the problems of solder joint embrittlement and stress concentration, thereby significantly improving the mechanical strength and electrical reliability of the connection.
3. Precision tin plating treatment: This is the core advantage of “tinned copper foil soft connection”. After pressure welding and forming, or during the manufacturing process of the copper foil body, the surface of the copper foil is uniformly tinned. Tin layers have the following significant advantages:
   • Excellent oxidation resistance: Tin is not easy to oxidize in the air and can effectively protect the copper inside from oxidation, thereby maintaining good electrical conductivity for a long time, especially in humid or dusty environments.
   • excellent corrosion resistance: The tin layer has good corrosion resistance to a variety of chemical media, extending the service life of the product under harsh working conditions.
   • lower contact resistance: Tin plating helps reduce the contact resistance of the connection terminal, ensures smoother current transmission, and reduces heat generation and energy loss.
   • good weldability: Tin-plated surfaces make it easier to carry out subsequent connection operations such as brazing.

Technical data and customization options

We offer a variety of technical specifications and highly customized options to meet the most demanding application needs:

• 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 。Combinations of different sheet thicknesses can achieve different current carrying capabilities and flexibility
• surface treatment: MainlyTin plating (X) 。In addition, bare copper and nickel plating (N) are also available , Silver plating (Y) , paste nickel sheet, paste silver sheet Options such as options to meet specific environmental or performance requirements.
• cross-sectional area: Product cross-sectional areas range from 10mm² to 5000mm² , can meet various low voltage, medium voltage and even high voltage and large current transmission needs.
• Geometric size and terminal design: We fully support non-standard customization 。

product advantages

• Excellent electrical conductivity: High-purity T2 copper substrate and low-resistance pressure welding process ensure efficient current transmission.
• Enhanced oxidation and corrosion resistance: Tin plating is the most important advantage of this product. It provides strong protection for copper and significantly extends the service life of the product in humid, oxidizing or certain corrosive environments.
• Excellent flexibility and vibration resistance: The multilayer copper foil laminated structure gives the product excellent flexibility, which can effectively absorb and compensate for vibration, displacement, thermal expansion and contraction generated by the equipment during operation, and avoid the risk of fracture of hard connections.
• High reliability and stability: The molecular bond formed by the pressure welding process makes the contact surface more uniform and stable, avoiding problems such as false welding and poor contact, thereby greatly improving the service life of the product and the operating reliability of the system.
• good heat dissipation performance: Copper itself has excellent thermal conductivity, combined with a good contact surface and small resistance, which helps quickly dissipate the heat generated during operation and avoid local overheating.
• convenient installation: Standardized connection terminal design allows the product to perfectly match with various standard bolts or terminals, making the installation process quick and easy.
• highly customized: Fully support customization of drawings and samples , meet various non-standard and special application needs.

application field

Due to its excellent performance and reliability, tin-plated copper foil soft connections are widely used in key industries with extremely high requirements for electrical connections ：

• new energy vehicles: As a key flexible connection between the power battery pack, drive motor, inverter and charger, it handles high currents, high vibrations and complex environmental conditions.
• wind power: Used inside wind turbines, connecting key components such as generators, converters, and transformers to effectively compensate for vibration and thermal expansion and cold contraction.
• Photovoltaic energy storage system: Provide efficient, reliable and environmentally resistant current transmission paths in photovoltaic inverters, junction boxes and large energy storage battery systems.
• Electric locomotives and rail transportation: Used in the conduction and grounding systems of electrified railway locomotives and the traction power supply systems of urban rail transit to cope with complex operating environments and high current shocks.
• High and low voltage switchgear: Used as a flexible connection in various switchgear, circuit breakers, and bus ducts to solve equipment installation errors and operating vibration problems, and provide good anti-oxidation protection.
• Transformers and generators: As a flexible connection between large transformers, generators and external lines, it absorbs small displacements and vibrations during operation.
• Industrial automation and robots: Provide reliable electrical connections in automated equipment and robot joints that require flexible movement and high current transmission.
• Data centers and UPS systems: Ensure the stability and safety of power transmission in high-current distribution cabinets, UPS power supplies and battery pack connections.

Reasons to choose us

Relying on our years of industry experience and advanced production technology, we are committed to providing customers with the best quality automotive battery soft connection products. We strictly control every aspect from raw material procurement to finished product delivery to ensure that every product meets strict industry standards. Choosing us means choosing reliable quality, professional services and continuous innovation.

service support

We are committed to providing professional and efficient systematic service support to customers around the world 。From early technical consultation and customized plan design, to manufacturing, quality control and perfect after-sales service, we will follow up the entire process to ensure that we provide you with the best quality products and the most satisfactory cooperation experience. You are welcome to provide detailed drawings and samples , our professional team will be happy to tailor the copper foil soft connection solution that best meets your needs.