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Flexible Copper Busbar
Our Flexible Busbar is specially designed to meet the demanding requirements of new energy vehicles, offering superior electrical performance and mechanical reliability. Manufactured using advanced multi-layer copper lamination technology, this busbar ensures excellent conductivity and efficient current distribution with minimal resistance.
Industry-Standard Design: Engineered in accordance with the latest automotive and battery industry standards, our Flexible Busbars comply with strict electrical safety and thermal management requirements critical for electric vehicle battery systems.
Customizable Solutions: We provide tailored busbar designs to match your specific project needs. Whether it’s adapting thickness, length, or shape, our Flexible Busbars can be customized for different current ratings and installation environments, ensuring optimal integration into your battery pack or powertrain system.
High Durability and Flexibility: The laminated copper layers, combined with high-quality insulating materials, offer excellent flexibility to accommodate complex vehicle designs while maintaining structural integrity under vibration and thermal cycling.
Certified Quality: Our production process is certified under ISO 9001 quality management standards. Additionally, our flexible busbars meet CE and RoHS certification requirements, guaranteeing safety, reliability, and environmental compliance.
Application Scope: Ideal for electric vehicles (EV), hybrid electric vehicles (HEV), battery energy storage systems (BESS), and other new energy applications requiring high-performance conductive connections.
| Parameter | Specification Range / Details |
|---|---|
| Material | Oxygen-Free High Conductivity Copper (OFHC), ≥99.99% purity |
| Copper Layer Thickness | 0.1 mm – 1.5 mm (customizable per layer) |
| Number of Layers | 3 – 7 layers (based on current capacity and design) |
| Total Thickness | 0.5 mm – 10 mm (depending on layers and insulation) |
| Width | 10 mm – 100 mm (customizable) |
| Length | Up to 1000 mm (customizable) |
| Current Rating | Up to 500 A+ (depending on thickness, width, and layers) |
| Voltage Rating | Up to 1000 V DC |
| Insulation Material | High-temperature resistant polymer films (e.g., PET, PI) |
| Operating Temperature | -40°C to +125°C |
| Thermal Conductivity | ≥ 200 W/m·K (depends on copper thickness) |
| Electrical Resistance | < 0.1 mΩ (design-dependent) |
| Tensile Strength | ≥ 200 MPa (depending on copper quality and lamination) |
| Bending Radius | ≥ 5 × total thickness (to maintain integrity) |
| Surface Treatment | Tin plating, Silver plating (optional for corrosion resistance) |
| Certifications | ISO 9001:2015, CE, RoHS compliant |
| Testing Standards | Vibration, Thermal Cycling, Insulation Resistance per automotive standards |
Our Flexible Busbars are engineered to meet the demanding electrical and mechanical requirements of new energy applications, ensuring reliable and efficient power distribution in various critical systems:
Electric Vehicle (EV) Battery Packs
Flexible busbars serve as essential conductive pathways connecting individual battery cells or modules within high-voltage lithium-ion battery packs. Their excellent flexibility allows for compact, space-saving designs that accommodate complex battery layouts while maintaining stable current flow and minimizing energy loss.
Hybrid Electric Vehicles (HEV) and Plug-in Hybrid Electric Vehicles (PHEV)
In HEVs and PHEVs, flexible busbars facilitate high-current connections between the battery, inverter, and electric motor components. Their robust mechanical properties ensure resistance to vibration and thermal cycling, which is vital in dynamic automotive environments.
Battery Energy Storage Systems (BESS)
Large-scale stationary energy storage solutions rely on flexible busbars for efficient power distribution between multiple battery modules. The busbars’ customization options support diverse configurations, enabling scalable and maintainable energy storage architectures.
Charging Stations and Power Electronics
Flexible busbars are used inside fast charging stations and inverters to provide safe and reliable current pathways. Their high current capacity and insulation properties ensure efficient power handling and reduce risks of short circuits or overheating.
Renewable Energy Systems
In solar and wind power systems, flexible busbars enable efficient connection of battery storage units and power converters. Their durability under thermal and mechanical stress makes them suitable for harsh outdoor environments.
Industrial Electric Vehicles and Equipment
Forklifts, automated guided vehicles (AGVs), and other industrial EVs use flexible busbars for battery interconnections, benefiting from their compactness, flexibility, and durability to withstand demanding operational conditions.
Q1: What materials are used in your flexible busbars?
A1: We use high-purity oxygen-free copper (OFHC) for the conductive layers and high-temperature resistant insulating polymer films such as PET or polyimide to ensure excellent electrical performance and durability.
Q2: Can the flexible busbar be customized?
A2: Yes, we offer full customization on dimensions (thickness, width, length), number of copper layers, surface treatments, and shape to meet your specific application and current requirements.
Q3: What is the maximum current rating of your flexible busbars?
A3: Depending on design, thickness, and layer count, our busbars can handle current ratings up to 500A or higher. We work closely with customers to design the optimal solution for their load needs.
Q4: What certifications do your flexible busbars have?
A4: Our products comply with ISO 9001:2015 quality management standards and carry CE and RoHS certifications. They also meet automotive industry testing requirements including vibration and thermal cycling tests.
Q5: What is the typical operating temperature range?
A5: Our flexible busbars operate reliably in temperatures ranging from -40°C to +125°C, suitable for the demanding conditions in automotive battery systems.
Q6: How do you ensure the durability of flexible busbars under vibration and bending?
A6: The multi-layer laminated structure combined with flexible insulating films provides excellent bending fatigue resistance and mechanical strength, ensuring long-term reliability even under harsh vibration and thermal cycling.
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