Copper Foil Flexible Busbar For Traction Converter Application

The Traction Converter Copper Foil Flexible Busbar is a core electrical component specifically designed for rail transit traction converters—including high-speed EMUs, electric locomotives, subways, light rail, and urban rail vehicles.

It serves as a flexible conductive connection between key components such as IGBT power modules, DC busbars, and energy storage capacitor banks, effectively solving the pain points of vibration resistance, thermal expansion compensation, and compact space installation in on-board harsh environments. With advanced diffusion welding technology and high-purity copper materials, it ensures stable current transmission, low energy loss, and long service life.

The busbar can be totally customized according to customer drawing (length, width, thickness, hole number & diameter)

Available Treatments: Tin Plating | Silver Plating | Nickel Plating

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Product Details

Copper Foil Flexible Busbar For Traction Converter Application

Technical Specifications

Item	Specification	Remarks
Base Material	T2 High-Purity Copper Foil (Cu ≥ 99.95%)	Conductivity ≥ 98% IACS, ensuring low resistance and high efficiency
Copper Foil Thickness	0.1mm / 0.2mm (Customizable: 0.05-0.5mm)	Multi-layer lamination for flexibility and vibration resistance
Rated Current	500A - 2500A	Customizable according to traction converter power requirements
Rated Voltage	DC 1500V / 1800V (Mainstream), up to 35kV (Customizable)	Complies with IEC 61210 voltage standards
Working Temperature	-40℃ ~ +125℃	Adapts to extreme on-board temperature changes
Insulation Sheath	Silicone Rubber / PTFE, Flame Retardant V-0	High temperature resistance, anti-corrosion, halogen-free optional
Termination Process	Seamless Molecular Diffusion Welding / Cold Pressure Welding	No false welding, no oxidation, high mechanical strength
Surface Treatment	Tin-Plated / Silver-Plated / Bare Copper	Anti-oxidation, reducing contact resistance
Vibration Resistance	≥ 500,000 Vibration Cycles	Absorbs train Jolting and high-frequency vibration, no breakage
Parasitic Inductance	< 5nH	Protects IGBT modules from voltage spikes
Service Life	≥ 10 Years	Under normal on-board working conditions

The Core Applications

Connection between IGBT power modules and positive/negative DC busbars
Flexible connection between energy storage capacitor banks and main busbars
Power circuit transfer between rectifier and inverter units
Flexible transition for incoming and outgoing lines of converter cabinets
Shockproof conductive connection for water-cooled power components

Suitable for: High-speed EMUs, Electric Locomotives, Subway Trains, Light Rail, Urban Rail Vehicles, Regional Trains

1. Customization Process (Simple & Efficient)

Requirement Submission: You provide detailed requirements (equipment drawings, current/voltage parameters, structural dimensions, working environment, etc.).
Scheme Design: Our engineering team completes the customized design and issues a design drawing within 1 working days for your confirmation.
Sample Confirmation: We produce customized samples (3-5 working days) for your performance testing; adjust the design according to your feedback until it meets your requirements.
Mass Production: After sample confirmation, we start mass production, strictly controlling quality and delivering on time (10-20 working days).

2. Structural Design Customization

Shape & Bending: Free customization of length (50mm-2000mm), bending angle (0°-180°), and bending position to fit the compact space of under-car traction converters.
Mounting Structure: Customization of mounting hole size, hole distance, and terminal thickness according to your equipment installation drawings, ensuring seamless connection with IGBT modules, busbars, and capacitor banks.