What are the structure and advantages of copper busbar soft connection?

What is a flexible copper busbar connector?

A flexible copper busbar connector, also known as a copper braid flexible connector or a flexible copper busbar connector, is a flexible conductor used to connect two electrical devices or components.

Its core function is to provide a low-resistance, high-current-carrying, and flexible electrical path between fixed, rigid copper busbars (or device terminals) that may move relative to each other due to thermal expansion and contraction, vibration, or installation errors.

Main Structure and Materials

Conductor:

Material: Typically made of high-purity T2 copper due to its extremely high conductivity (over 98%).

Form: Made of multiple layers of extremely thin copper foil or fine, flexible copper braided wire. This structure imparts excellent flexibility and fatigue resistance.

Terminal:

Solid copper terminals are crimped or welded to each end of the flexible connector using a specialized process (such as molecular diffusion welding).

Terminal Type: Available in flat (for bolted connections), round (for nailed connections), or with a specific interface shape, and are often pre-drilled for easy installation.

Surface Treatment: To enhance corrosion resistance and reduce contact resistance, terminals are often plated with tin, silver, or nickel.

 

Core Features and Advantages

Excellent Flexibility & Vibration Resistance:

Compensates for dimensional changes caused by temperature fluctuations (thermal expansion and contraction) in equipment, preventing excessive mechanical stress at connection points.

Effectively absorbs and cushions vibrations generated during equipment operation, preventing bolt loosening and fatigue fracture at connection points.

High Conductivity & Current Carrying Capacity:

Made of high-quality copper, it offers extremely low resistance, minimizing temperature rise and reducing energy loss when high currents flow through it.

The cross-sectional area can be flexibly designed based on current flow, capable of handling currents from tens to thousands of amperes.

Easy Installation and High Fault Tolerance:

Because of its flexibility, precise alignment of the two connection points is not required during installation, allowing for easy adjustment, greatly facilitating on-site installation.

High Reliability and Long Life:

Professional manufacturing processes (such as molecular diffusion welding) ensure a secure bond between the terminal and the flexible body, stable resistance, and resistance to breakage.

 

Main Application Areas

 

Copper busbar flexible connectors are indispensable components in modern power systems and industrial equipment, and are widely used in the following applications:

New Energy Industry:

Power battery packs: Connect cells and modules, absorbing expansion and contraction during battery charging and discharging.

New Energy Vehicles: Connect high-voltage components such as motors, controllers, and battery packs.

Power Systems:

Substations: Connect transformers, circuit breakers, and disconnectors.

Generators: Connect generator output terminals to busbars.

Industrial Equipment:

Inverters and Servo Drives: Connect internal DC bus capacitors to IGBT modules.

High-power welding equipment and induction heating equipment.

Electric locomotives and rail transit.

Others:

Any fixed connection point requiring high current and subject to vibration or thermal displacement.

 

Manufacturing Process

High-quality copper busbar flexible connectors are typically manufactured using a molecular diffusion bonding process:

The ends of multiple layers of copper foil or braided wire are cleaned and neatly stacked.

Then they are placed in a specialized diffusion bonding machine and subjected to high temperature, high pressure, and a specific atmosphere for a period of time.

Under pressure, copper atoms diffuse across the interface, forming a solid metallic bond with electrical conductivity and mechanical strength nearly identical to those of the parent material.

Compared to traditional riveting or screw crimping, this process offers lower resistance, more reliable connections, and longer life.

 

Selection Key Points

When selecting a copper busbar flexible connector, consider the following key parameters:

Current-carrying capacity (rated current): Determine the required cross-sectional area based on the maximum current flowing through it.

Flexible connector length: Determine based on the actual distance between the two connection points and the expected displacement.

Terminal type and size: Match the terminal type and bolt hole spacing of the connected equipment.

Bending direction and number of times: Determine the required bending direction after installation and the expected vibration frequency during equipment operation.

Surface treatment: Select the appropriate coating based on the operating environment (such as humidity, salt spray, and chemical gases).

Certification requirements: Certain industries (such as automotive and rail transportation) may require compliance with specific industry standards (such as ISO, UL, and VDE).

 

Summary

In summary, the copper busbar flexible connector is a seemingly simple but highly technologically advanced electrical connection component. Its unique flexible structure solves the stress, vibration, and thermal displacement issues associated with rigid connections in high-current systems, making it a key component for ensuring the safe, stable, and long-term operation of electrical equipment.

If you would like to learn more about,please contact at:pannie@hdswitchgear.com.