| Customization: | Available |
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| Surface Treatment: | Copper |
| Certification: | ISO9001 |
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Flexible busbar is through brazing the copper foil parts together,which is 99.9% copper contented. It capitals the products excellect conductivity with less impurities. Laminated copper busbar have more current carrying surface area.
Copper foil: 0.05mm to 0.3mm thick. The contact surface can be tinned or silvered according to the user's requirements.The current is based on the customer's requirement of 1 square knitting belt & the effective loads current 4A calculation. Copper conductors with different sectional areas have different parameters. The large area can be multi-layer or set.The price depends on the current copper price and current size.
| Material Standard | GB : T2 Copper with Min. 99.9% DIN: E-Cu58 (Number: 2.0065) EN: Cu-ETP ( Number: CW004A) ISO: Cu-ETP UNS: C11000 JIS: C1100 BS: C101 Other Material also can be customized |
| Resistance | 0.00001Ω |
| Conductivity | 57% |
| Copper Foil of Single Layer Thickness |
0.1/0.2/0.3/0.5/1.0mm,depend on bus bar structure, we will advise suitable thickness |
| Insulation Material | PVC Dipping Coating is good performance, Special shaped bus bar can be put on directly, it is not easy to break when it be bent with many times. |
| Insulation Performance | PE and PVC are good, PVC dipping is better than PE heat shrink tubes |
| Flame Retardant/Fire Resistance | UL94-V-0 or upon you request |
| Leakage Testing | PVC Dipping Sleeves: In condition of 3500VDC with 30s upon thickness 1.5mm, Leakage is 0.025 MA; In condition of 5000 VAC with 30s to 60s upon thickness 1.8mm to 2.0mm, Leakage is 0.065 MA; Or upon your working voltage, we advise to choose better solution. |
| Surface Plating | Nickel, tin or silver plated etc Plating Thickness:Normally 3um to 12um or upon customers' request |
| Salt Spray Testing | In a neutral environment, nickel can bear 240 hours. Silver is lower, tin is lowest |
| Bending Testing | Bend 10000 times in 15 radian angle without breakage or fracture. |
| Temperature Rise Testing | Depend on flexible busbar cross-sectional area, We can offer all temperature rising test report before delivery if you request |
| Operating Temperature | -45 to +150 ºC |
| Copper Foil Tensile Strength | ≥500N |
| Quote Time | Quotation sheet will be sent in 1-3 working days when receive your enqiury |
| Sample/Trial Order Delivery Time |
In 5 -15 working days according to different bus bar structure and manufacture process |
| Quality Management Standard | Meet Auto Industry IATF 16949 |
| Eco-friendly Certificate | ROHS, REACH |
The manufacturing process of flexible copper busbars involves several key steps to ensure conductivity, flexibility, and durability. Below is a structured workflow:
1. Material Selection
- Copper Type: High-purity electrolytic copper (≥99.9% Cu) for optimal conductivity.
- Form: Typically tinned or bare copper strips/braids for flexibility.
2. Cutting & Shearing
- Copper strips/braids are cut to required lengths using precision shearing machines.
- Laser/CNC cutting ensures dimensional accuracy.
3. Surface Treatment (Optional)
- Tinning: Electroplating with tin (Sn) to prevent oxidation.
- Electro-polishing: For improved surface smoothness.
- Cleaning: Degreasing to remove contaminants.
4. Braiding/Layering (For Flexible Sections)
- Multiple thin copper strands are braided or laminated for flexibility.
- Ensures vibration resistance and thermal expansion handling.
5. Terminal Attachment
- Crimping/Welding: Copper lugs or terminals are attached via:
- Ultrasonic welding (for high-current applications).
- Hydraulic crimping (for secure mechanical joints).
- Soldering: For smaller busbars (optional).
6. Insulation (If Required)
- Heat-shrink tubing for partial insulation.
- PVC/Silicone coating for full insulation.
- Epoxy resin for rigid-flex designs.
7. Quality Testing
- Conductivity Test: Measures resistance (Ohm's law).
- Flex Test: Repeated bending to check durability.
- Pull Test: Ensures terminal strength.
- Thermal Imaging: Detects hotspots under load.
8. Final Assembly & Packaging
- Labeling, barcoding, and packaging for shipment.
- Compliance checks (e.g., IEC 60439, UL standards).
New energy vehicle; Battery packs; Power supply room; Power distribution equipments;
Switchboards;Panel boards; Low and medium voltage switchgear;
Low voltage distribution; High current & control equipment; Busway systems etc.
1.Perfect management systems: Implement ISO9001 & IATF16949 and provide PPAP document.
2.Professional sales team:more than 6 year export experience and 24-hour service line to meet customer's need.
3.Premium quality:test from raw material to packaging and many advanced testing equipments,like temperature tester,electrical conductivity tester.
4.High production efficiency and low cost :10 year experience of production and complete production chain.
5.Highly intelligent production workshop: robot production line and high-precision machines.
1.Q:Can it be customized according to our drawings?
A:As long as you send us the drawings that need to be customized, we can give you the best quotation. Attention, please provide copper standard, related process requirements and order quantity.
2.Q:Can you provide samples?
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