Custom Flexible Copper Foil Connections for Motor Controllers - Quality from China Suppliers & Factory
Special Copper Foil Flexible Connection for Motor Controller (MCU)
Material Specifications
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Base Material: T2 high-purity copper foil (copper content ≥99.95%, conductivity ≥97% IACS)
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Copper Foil Thickness: 0.05/0.1/0.2mm (0.1mm as standard)
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Number of Layers: 20–100 layers (customized according to current)
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Cross-Section Dimensions: Width 20–100mm, total thickness 1–10mm
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Standard Length: 50–300mm (customizable)
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Terminal Dimensions: Customized according to MCU interface (aperture φ5–φ12mm, hole spacing accurately matched)
Electrical Performance
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Rated Current: 300–1500A (600/800/1000A commonly used for MCU)
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Contact Resistance: ≤40μΩ (@20℃, silver-plated terminals)
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Insulation Withstand Voltage: AC 3000V/1min (no breakdown)
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Insulation Resistance: ≥500MΩ
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Flame Retardant Grade: V–0 (GB/T 2408)
Mechanical & Environmental Performance
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Bending Radius: ≥2×bandwidth (no fracture after ≥50,000 dynamic bends)
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Operating Temperature: -40℃ ~ +125℃ (vehicle-grade)
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Surface Treatment: Bare copper / Tin-plated / Silver-plated (recommended)
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Insulation Sheath: Silicone rubber/fluororubber/heat shrink tube (oil-resistant, high and low temperature resistant)
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Salt Spray Resistance: ≥500h (silver-plated/nickel-plated)
Typical Application Scenarios
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New Energy Passenger/Cargo Vehicle MCU: IGBT module → three-phase output terminals
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Inside Motor Controller: Busbar confluence, capacitor module connection
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Electric Drive Assembly: High-voltage connection between MCU → drive motor
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Energy Storage/Industrial Control: High-current flexible connection for high-power frequency
Package & Shipment:
Frequently Asked Questions (FAQ)
Q:
What is the base material used for the MCU flexible connection?
The flexible connection is made from T2 high-purity copper foil, which features a copper content of ≥99.95% and a conductivity of ≥97% IACS.
Q:
What are the standard copper foil thickness and layer options?
Standard copper foil thickness options are 0.05mm, 0.1mm, and 0.2mm (with 0.1mm as the standard design). The number of layers can range from 20 to 100 layers, customized to meet specific current requirements.
Q:
What is the rated current range and contact resistance?
The rated current capacity spans from 300A to 1500A (with 600/800/1000A commonly used for motor controllers). The contact resistance is ≤40μΩ at 20℃ when using silver-plated terminals.
Q:
How durable is the connection under dynamic bending?
It has a bending radius of ≥2×bandwidth and is designed to undergo ≥50,000 dynamic bends without experiencing any fracture.
Q:
What operating temperature and environmental conditions can it withstand?
It is vehicle-grade and supports an operating temperature range of -40℃ to +125℃. With silver-plated or nickel-plated surfaces, it provides a salt spray resistance of ≥500 hours.