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    Copper Foil Flexible Busbar for 35kV / 110kV / 220kV New Energy Collector Step-Up Substations

    Copper foil flexible busbar (also called laminated copper expansion joint) specially customized for new energy PV & wind power collector step-up substations, main transformers, high-voltage switchgear and SVG reactive compensation cabinets.Made of multi-layer T2 high-purity oxygen-free copper foil integrated by molecular diffusion welding, it effectively solves core pain points of rigid copper busbars: thermal expansion displacement, equipment vibration transfer, seismic hidden danger, narrow cabinet wiring and high harmonic loss.

    Widely matched with 35kV, 110kV, 220kV centralized PV stations, wind farm booster stations and grid-side energy storage supporting substations, it acts as a safe buffer conductive connector between transformers, bus bridges and power modules.

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      Product Details

      Copper Foil Flexible Busbar for 35kV / 110kV / 220kV New Energy Collector Step-Up Substations

      Technical Specifications & Customizable Parameters

      Base Material

      T2 oxygen-free copper foil, single foil thickness: 0.1mm / 0.2mm/0.3mm(standard), customized 0.05~0.5mm

      Size Customization

      • Width: 10–150mm
      • Total thickness (layers): 10–200 layers (matched with 50A–5000A rated current)
      • Total length, bending shape, hole position / hole diameter / hole quantity: fully customized per CAD drawing

      Surface Plating Option

      1. Bare copper: clean indoor dry switch cabinet
      2. Tin plating: general inland substation, cost-effective anti-oxidation
      3. Nickel plating: coastal high salt fog PV booster station, long-term anti-corrosion
      4. Silver plating: ultra-low resistance high-precision SVG power module

      Core Application Scenarios for Substation

      1
      Main Transformer HV & LV Side Expansion Joints
      Compensate thermal expansion & cold contraction displacement during transformer full-load operation, isolate vibration transmission from transformer body to rigid busbar, improve substation seismic resistance, eliminate busbar cracking risk caused by resonance or earthquake.
      2
      Transition Connector for High-Voltage Switchgear Bus Bridge
      Absorb cabinet assembly dimensional deviation and long-term running vibration, reduce faults like loose bolts and overheated contact points, lower daily inspection & maintenance workload.
      3
      Internal Connection for SVG Reactive Power Compensation Cabinet
      Custom special-shaped bent flexible busbar adapts compact cabinet inner space, optimize wiring layout, shorten conductive loop, cut harmonic loss and stabilize temperature rise of IGBT power modules.

      Core Production Technology – Integrated Molecular Diffusion Welding

      All terminals adopt one-time molecular diffusion welding without cold solder joint or delamination between copper foil layers. Under high temperature & high pressure, copper molecules interpenetrate to form an integrated conductive surface, guaranteeing stable low resistance under long-term heavy current, avoiding local overheating and arcing risk.

      Packing & Shipment

      Inner package
      plastic bag anti-scratch protection
      Outer package
      export neutral carton / plywood case for heavy large-size products
      Marking
      brand, model, quantity, size, customer label customizable
      Shipment
      sea freight, air freight, express delivery supported