热缩绝缘铜母排

Flexible 铜母排 are widely used in new energy applications such as battery packs. Their unit price is typically 1.5–2× higher than rigid 铜母排, primarily due to higher process complexity. The following summarizes their core application value, structure, and technical requirements.

结构组成

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.

技术要求

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

应用

1) Battery Pack 应用

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.

电动汽车、变压器与配电柜

折弯、冲孔、焊接、铆接、浸涂都在厂内完成，并引入自动机器人提升产能。工程团队协助客户控制成本并保持连接稳定。