Sticking nickel sheet copper foil soft connection 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 element in the field of electrical connection. It aims to solve connection problems caused by vibration, displacement or thermal expansion and contraction during operation of equipment. and

Soft connection with nickel sheet copper foilOn this basis, innovative upgrades have been carried out. By accurately attaching a layer of nickel sheets to both ends of the copper foil soft connection or specific connection surfaces, the product’s corrosion resistance, high temperature resistance and high frequency applications have been significantly improved. Electrical stability in high-frequency applications. 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 technologies: high-purity copper foil, precision pressure welding and nickel sheet strengthening

This product combines multiple key technologies to ensure excellent performance in harsh environments:

1. High-purity T2 purple copper foil substrate: 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 electrical resistance, reduce energy loss, and help quickly dissipate heat generated during operation.
2. Molecular diffusion welding (pressure welding) process: The connection areas at both ends of the soft connection body adopt a special pressure welding process 。This technology promotes diffusion movement between copper foil molecules through high temperature and high pressure and penetrates into each other to form 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 nickel sheet bonding technology: This is the core innovation of “soft connection with nickel sheet and copper foil”. Accurately attach a layer of nickel sheet to the surface of the press-bonded connecting terminal, or in a specific position according to customer needs. Nickel sheet has the following significant advantages:
   • Excellent corrosion resistance: Nickel is a highly inert metal with excellent oxidation resistance and resistance to various acid and alkali corrosion. In humid, chemical corrosion or high temperature and high humidity environments, nickel sheets can effectively protect the internal copper and extend product life 。
   • excellent high temperature resistance: The melting point of nickel is higher than that of copper and tin. It can maintain better physical and chemical stability under high temperature environments, prevent oxidation or deformation of terminals at high temperatures, and ensure connection reliability.
   • Enhanced mechanical strength and wear resistance: The nickel layer has high hardness, which can increase the surface hardness and wear resistance of the connecting end and improve the durability of the product under frequent insertion and removal or friction environments.
   • magnetic shielding performance: In certain applications, the magnetic properties of nickel can also provide a certain magnetic shielding effect.
   • Stability of low contact resistance: The passivation film formed on the surface of the nickel layer is very thin and stable, which can maintain a low contact resistance for a long time and ensure the stability of current transmission.

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 。Different combinations of individual thicknesses can achieve different current carrying capabilities and flexibility.
• surface treatment：nickel sheet
• 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.
• Excellent corrosion and high temperature resistance: Nickel sheet provides a strong protective layer that significantly enhances product performance and service life in corrosive environments, high temperatures or high humidity conditions 。
• Excellent flexibility and vibration resistance: The multi-layer copper foil 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 incoming drawings and samples to meet various non-standard and special application needs 。

application field

With its excellent performance and reliability, nickel-bonded copper foil soft connections are especially suitable for key industries with strict requirements for corrosion resistance, high temperature resistance and high reliability:

• new energy vehicles: As a key flexible connection between the power battery pack, drive motor, inverter and charger, it responds to high current, high vibration, high temperature and possible corrosive environments in the battery compartment.
• wind power: Used inside wind turbines, connecting key components such as generators, converters, and transformers to effectively compensate for vibration, thermal expansion and cold contraction, and can withstand harsh natural environments such as damp heat and salt fog.
• Photovoltaic energy storage system: Provide efficient, reliable and environmentally resistant current transmission paths in photovoltaic inverters, junction boxes and large energy storage battery systems, especially in outdoor and high temperature conditions.
• 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 while ensuring long-term stable operation.
• High and low voltage switchgear: Used as a flexible connection in various switchgear, circuit breakers, and bus ducts, solves equipment installation errors and operating vibration problems, and provides good anti-corrosion protection.
• Industrial automation and robots: Provide reliable electrical connections in automated equipment and robot joints that require flexible movement, high current transmission, and may be exposed to corrosive gases or high temperatures.
• Electroplating equipment and chemical industry: Due to the excellent corrosion resistance of nickel sheets, it is very suitable for applications such as electroplating power supplies and chemical equipment that require extremely high corrosion resistance of materials.
• High temperature furnaces and heating equipment: In high temperature working environments, nickel sheets can effectively protect copper materials and extend the service life of connectors.