Flexible busbar laminated insulating flexible busbar

When placing an order, please specify the following values:
Length (L) x width (W) x number of layers (H) x single layer thickness (H1)

Product shape and hole type
Aperture (d)
Single sheet thickness (regular 1 mm)

The flexible bus bar is a flexible conductive connection made by laminating multiple thin copper foils/tapes and extruding them.

It has high flexibility, high mechanical strength, high extensibility, and high conductivity. It can be bent, twisted and folded greatly, which has the advantages of saving space, saving costs and being easy to install compared with cables. Compared with copper bars, it has the advantages of flexibility, flexible layout, cleanliness and beauty, and easy installation.

Note: The above data are the theoretical calculation values of corresponding temperature rise at normal temperature. More parameters can be customized.

What is a flexible busbar?

The flexible bus bar is made of multiple thin copper foils/tapes that are superimposed and extruded, and has excellent electrical and mechanical properties. It uses T2 copper as the substrate (copper content ≥ 99.95%). The size and number of layers can be customized according to customer needs. The surface can be tinned or kept bare copper. Compared with traditional cables and rigid busbars, flexible busbars perform particularly well in environments with high current distribution and space constraints, and are widely used in new energy, industrial control, power distribution and other fields.

Features and advantages of flexible bus:

• Excellent flexibility and plasticity: The laminated copper foil structure can be greatly bent, twisted and folded to adapt to complex routing requirements.
• High mechanical strength and extensibility: Multi-layer copper foils are tightly bonded, excellent fatigue resistance and long life.
• Excellent conductivity: T2 grade copper material and large cross-section, low resistance and low heat generation, ensuring stable operation of the system.
• Save space and cost: Compared with cables with equal current levels, the volume occupied can be reduced; compared with copper bars, installation is easier and layout is cleaner.
• Easy installation: There is no need to peel insulation or remove protective covers, and the terminal can be directly fixed to complete the connection, greatly reducing the difficulty and time of on-site construction.

application scenarios

photovoltaic power generation system: PV junction box, inverter side high-current connection.

energy storage power station: Connection between buses and modules within the battery pack.

Data Center and UPS: Highly reliable power distribution.

Rail transit and electric vehicles: Current transmission in high-frequency vibration environments for power and auxiliary systems.

industrial automation: Current distribution in narrow spaces within machine tools, robots and other equipment.

Distribution cabinet/switch cabinet: Modular wiring and grounding system.

Frequently asked questions:

Q1: How to select the flexible busbar specification based on the current level?
A1: It mainly depends on the cross-sectional area (mm ²) and the matching of rated current; the current carrying capacity under different temperature rise Δ T conditions (11 K, 18 K, 30 K, 50 K) has been given in the picture parameter table, and it is recommended to select according to the range of 18 K~30 K.

Q2: Can flexible bus bars be used in high temperature environments?
A2: T2 copper has excellent heat resistance, and the continuous working temperature can reach above +90 ℃ (practical applications need to consider the performance of insulating materials).

Q3: How to deal with the ends of flexible buses?
A3: The end can be riveted or copper end cold pressing process to ensure low contact resistance.

Q4: Are finished assemblies and supporting terminals provided?
A4: It can be customized according to drawings, and equipped with corresponding models of terminals and crimping kits to improve on-site construction efficiency.

Q5: Does long-term operation require maintenance?
A5: The flexible bus itself does not require additional maintenance, but it is recommended to regularly check the terminal tightening torque and insulation integrity.

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.[/vc_column_text][/vc_column][/vc_row]