High-Performance Copper Foil Flexible Busbar for High Current Applications - China Suppliers and Factory
Technical Parameters For Copper Foil Flexible Busbar
Item |
Specification |
| Material | T2/TU2 Copper (C11000/C10100) |
| Single Foil Thickness | 0.05–0.5mm (0.1mm standard) |
| Cross-Section Area | 1.5–5000mm² |
| Conductivity | ≥98% IACS |
| Working Temperature | -55°C ~ +125°C (up to 150°C for special insulation) |
| Insulation Withstand Voltage | Up to DC 4000V/1min (customizable) |
| Tensile Strength | ≥500N |
| Surface Plating | Tin / Nickel / Silver (custom optional) |
Main High-Current Applications
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New Energy Vehicles (EV): Battery module/pack connections, motor inverter, 800V high-voltage platforms
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Energy Storage Systems (ESS): Battery rack → PCS/inverter connections, large-scale energy storage cabinets
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Power & Industrial: Generators, transformers, high-voltage switchgear, large rectifiers, electrolysis equipment
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Rail Transit: Locomotive power distribution, metro vehicle electrical systems
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Data Centers & UPS: High-power power distribution, server room busbar connections
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Welding & Industrial Furnaces: Large welding machines, induction heating equipment
Order & Customization Guide
01
Dimensions: Total Length (L) × Width (W) × Total Thickness (T)
02
Welding Length (standard if not specified)
03
Hole Details: Quantity, diameter, position (drawing preferred)
04
Surface Treatment: Bare / Tin / Nickel / Silver
05
Insulation: Type (Heat Shrink / PVC Dipping) & color
06
Current Rating & Working Environment (for technical matching)
Why Choose Our Copper Foil Flexible Busbar?
🏭
Professional Customization
10+ years of R&D for high-current flexible connections
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Stable Performance
Low & stable contact resistance, long-term reliability
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Technical Support
Free design & solution consultation
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Lead Time
Fast delivery (7–8 working days)
Package & Shipment
Frequently Asked Questions (FAQ)
Q
What copper materials are used for your flexible busbars?
Our copper foil flexible busbars are made from T2 and TU2 copper, corresponding to international grades C11000 (electrolytic tough pitch copper) and C10100 (oxygen-free copper). Both grades deliver conductivity of ≥98% IACS, ensuring excellent electrical performance for high-current applications.
Q
Can the flexible busbar be customized to specific dimensions and hole patterns?
Yes. We fully support custom orders. Please provide the total length (L), width (W), total thickness (T), welding length, hole quantity, diameter, and position. Submitting a dimensional drawing is preferred to ensure accuracy. Cross-section areas from 1.5mm² up to 5000mm² are available.
Q
What surface treatment options are available?
We offer four surface treatment options: bare copper, tin plating, nickel plating, and silver plating. Each option provides different levels of oxidation resistance and contact performance. The appropriate choice depends on your working environment, temperature range, and connection requirements.
Q
What insulation types are available, and what voltage can they withstand?
We provide two main insulation types: heat shrink tubing and PVC dipping, available in various colors. The insulation withstand voltage can reach up to DC 4000V/1min and is fully customizable. For special high-temperature environments, insulation rated up to 150°C is also available.
Q
What is the typical lead time for a custom order?
Standard custom orders are typically completed and shipped within 7–8 working days after order confirmation and drawing approval. For urgent or large-volume orders, please contact us in advance so we can arrange production scheduling accordingly.
Q
Which industries and applications are your copper foil flexible busbars suitable for?
Our flexible busbars are widely used across multiple high-current industries, including new energy vehicles (EV battery packs, 800V platforms), energy storage systems (ESS), power generation and distribution equipment, rail transit, data centers and UPS systems, as well as industrial welding machines and induction heating furnaces.