Flexible busbars are made from laminated thin electrolytic copper, providing low resistance, efficient heat dissipation, and strong vibration resistance. With heat-shrink insulation, they ensure reliable power connections in EV systems, transformers, and distribution panels.
Flexible copper busbars are widely used in new energy applications such as battery packs. Their unit price is typically 1.5–2× higher than rigid copper busbars, primarily due to higher process complexity. The following summarizes their core application value, structure, and technical requirements.
1) Conductive Element
Depending on current requirements, composed of 10–50 layers of 0.1 mm T2 electrolytic copper foils (Cu ≥99.95%) laminated together. Nickel sheets are applied on the outer layers to enhance machinability and wear resistance.
2) Insulation Protection
Standard insulation uses EVA heat-shrink tubing (temperature range: –50 °C to 125 °C, dielectric withstand voltage: 4000 V DC, 1 min).
For high thermal insulation requirements, mica tape or ceramic composite tape is available.
1) Mechanical Performance
Peel strength: ≥50 N for laminated structure (tested by tensile testing machine)
Reliability: No internal fracture after fatigue oscillation testing; no delamination at copper–nickel bonding interfaces
2) Environmental Reliability
Salt spray resistance: Passes 72 h neutral salt spray test; appearance (excluding color change) and performance meet specifications after testing
3) Electrical Performance
Conductivity:
≥56 MS/m for thickness ≤1.5 mm
≥47 MS/m for thickness ＞1.5 mm
(tested by conductivity meter)
Rated current performance:
Under rated current operation, no damage, deformation, or plating peeling; temperature rise and insulation resistance meet applicable standards
Conductor Material: | Cu/Al Strip or Foil T2 (E-CU58, CU-ETP, C11000, C1100) TU2 (OF-CU, CU-OFE, CU-OF, C10100, C1011) Or other materials per your request. |
Welding Process： | Diffusion-bonded laminated joint |
Insulating Material: | Heat Shrink Tubes: PE/ EVA Insulation |
Surface Treatment: | Nickel/ Tin/ Silver plated or nickel tab lamination Plating Thickness: Normally 3um to 12um Or upon customers' request. |
Flame Retardant: | UL94 V-0 |
Punch Hole Design： | Holes are punched through the laminated foils and can be round or oblong as requested. |
Enterprise Certificate: | IATF16949, ISO45001, ISO14001 |
Eco-friendly Certificate: | RoHS, REACH |
Quote Response Time: | After receiving the drawings and verifying their feasibility, it will take 5-7 days to make a quotation. |
Delivery Time: | The delivery time will take about 15-20 days after payment. |
1) Battery Pack Applications
Supports multi-directional bending in compact layouts. Flexible forming compensates for busbar length tolerances, effectively providing assembly margin and improving installation efficiency.
2) Energy Storage Systems (ESS)
When carrying 200–800 A AC high current, the laminated copper foil structure improves current-carrying efficiency by mitigating skin effect.
3) Industrial Power Devices
Suitable for PV inverters, frequency converters, and similar equipment. The arched structure absorbs deformation caused by thermal expansion. With nickel-laminated surface treatment, salt spray resistance reaches ≥500 h, meeting 10-year service life requirements under –40 °C to 85 °C damp-heat environments.
