High-Performance China Suppliers Factory Special Copper Foil Flexible Connections for MCU in Electric Vehicle Motor Controllers
⚙️ 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 converters
📦 Package & Shipment:
❓ Frequently Asked Questions
Q
What is the copper purity of the base material used in these flexible connections?
We use T2 high-purity copper foil with a copper content of ≥99.95% and an electrical conductivity of ≥97% IACS, ensuring excellent current-carrying capacity and minimal energy loss in demanding MCU applications.
Q
Can the copper foil flexible connections be customized for different MCU interfaces?
Yes. Terminal dimensions, aperture size (φ5–φ12mm), hole spacing, width (20–100mm), total thickness (1–10mm), and length (50–300mm) are all fully customizable to match your specific MCU interface requirements.
Q
What surface treatment options are available, and which is recommended?
Three surface treatment options are available: bare copper, tin-plated, and silver-plated. Silver-plating is recommended for optimal contact resistance (≤40μΩ) and superior salt spray resistance (≥500h), making it ideal for vehicle-grade environments.
Q
How many bending cycles can these flexible connectors withstand?
Our copper foil flexible connections are engineered for durability, withstanding ≥50,000 dynamic bending cycles without fracture, provided the bending radius is maintained at ≥2× the bandwidth. This makes them well-suited for dynamic and vibration-prone environments.
Q
What is the operating temperature range, and are these connectors suitable for vehicle-grade use?
The operating temperature range is -40℃ to +125℃, fully meeting vehicle-grade standards. The insulation sheath options — silicone rubber, fluororubber, or heat shrink tube — provide additional resistance to oil, high temperatures, and low temperatures.
Q
What current ratings are available, and which are most commonly used for MCU applications?
The rated current range is 300A to 1500A. For motor controller (MCU) applications, 600A, 800A, and 1000A are the most commonly specified ratings, covering the majority of new energy passenger and commercial vehicle drive system requirements.