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High-Quality Copper Foil Flexible Busbar for Switchgear | China Suppliers & Factory for Low Inductance Solutions

Copper foil flexible busbars are expertly crafted from high-quality T2 (C11000) purple copper foil, serving as the primary conductor material. These busbars are comprised of multiple layers of copper foil sheets that are securely bonded through a molecular diffusion welding process. This technique involves pressing the copper foil layers together and forming them via high-current heating and pressure welding, ensuring exceptional conductivity and durability, Our copper foil flexible busbars are designed for use in a variety of applications, including switchgear, bus ducts, vacuum circuit breakers, and frequency converters. With a low inductance design, they significantly reduce switching losses and enhance electromagnetic compatibility. As a trusted factory and supplier in China, we are committed to providing high-quality solutions that meet the diverse needs of our customers in the electrical industry

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Product Details

Copper Foil Flexible Busbar Features

1. Outstanding Electrical Conductivity: Made from T2 purple copper foil with a copper content of ≥99.95%, the electrical conductivity at 20℃ is as high as 58×10⁶ S/m, and the resistance loss is as low as 0.1mΩ/m. The multi-layer parallel structure realizes the current-sharing design and can carry large currents ranging from several hundred to several thousand amperes.
2. High Reliability and Durability: By using the molecular diffusion welding process, a stable connection is formed between the copper foils, which can withstand frequent short-circuit impacts of over 100,000 times. The surface supports various treatments such as bare copper, tin plating, nickel plating, and silver plating. It has strong corrosion resistance and can adapt to extreme working environments ranging from -40℃ to +125℃. Its service life far exceeds that of traditional connection solutions.
3. Compact Design and Space Optimization: It combines high current transmission capacity with lightweight advantages (density only 8.9g/cm³), is small in size and doesn't take up much space. It can be adapted to compact layout scenarios such as battery modules and power equipment, while reducing the overall weight of the equipment.

Technical Data for Copper Foil Flexible Busbar

Material	T2 copper / C11000 / Cu-ETP 99.9% purity
Size	Customized
Finish	Bare, Tin Plating, Nickel Plating, Silver Plating
Single Foil Thickness	0.03mm; 0.05mm; 0.10mm (standard); 0.20mm; 0.30mm; 0.40mm; 0.50mm
Working Temperature	-50ºC to 115ºC
Ampacity	20A to 1500A
Inductance Value	Usually < 10nH (for high-frequency applications, it can be as low as < 5nH)

Customization Options for Copper Foil Flexible Busbar

The product has no fixed standard model and can be fully customized according to customer requirements.

📐 Size Customization Supports design of length, width and thickness as needed to adapt to different installation spaces.

🔩 Structural Customization Irregular structures, specific hole diameters and hole position layouts can be designed.

⚙️ Process Customization Optimize the number of layers and welding processes based on the usage scenarios.

🛡️ Surface Treatment Customization Select anti-corrosion and conductive treatment solutions such as tin plating, nickel plating, and silver plating as required.

Applications of Copper Foil Flexible Busbar

Energy Storage Systems: Used in photovoltaic energy storage combiner boxes and grid-type energy storage systems, supporting the rapid expansion of energy storage installed capacity. It has become a highly reliable connection solution recommended for grid-connected energy storage systems.

Industrial & Rail Transit: Suitable for industrial automation motor drives, transformer connections of welding machines, pantographs and traction converters of high-speed trains, and can withstand high-frequency dynamic connections and extreme working conditions.

Power Electronics: Widely applied in switchgear, bus ducts, vacuum circuit breakers, frequency converters, etc., it reduces switching losses through low-inductance design and optimizes electromagnetic compatibility.

Package & Shipping for Copper Foil Flexible Busbar

Frequently Asked Questions (FAQ)

Q What copper material is used in the flexible busbar, and what is its purity?

The copper foil flexible busbar is made from T2 purple copper (also known as C11000 / Cu-ETP), with a copper purity of ≥99.95%. This ensures excellent electrical conductivity of up to 58×10⁶ S/m at 20℃ and minimal resistance loss.

Q Can the copper foil flexible busbar be customized in size and structure?

Yes. The product has no fixed standard model and supports full customization. Customers can specify length, width, thickness, number of layers, hole diameters, hole positions, and irregular structural shapes to fit their specific installation requirements.

Q What surface treatment options are available for the flexible busbar?

The busbar supports multiple surface finish options including bare copper, tin plating, nickel plating, and silver plating. Each treatment offers different levels of corrosion resistance and conductivity performance to suit various application environments.

Q What is the operating temperature range and current capacity of the flexible busbar?

The copper foil flexible busbar can operate reliably in temperatures ranging from -50ºC to +115ºC. Its ampacity ranges from 20A to 1500A, making it suitable for a wide variety of low to high current applications.

Q What welding process is used, and how durable is the connection?

The copper foil layers are bonded using a molecular diffusion welding process, which creates a highly stable metallurgical connection. This allows the busbar to withstand over 100,000 frequent short-circuit impacts, ensuring long-term reliability far exceeding traditional connection solutions.

Q In which industries and applications is the copper foil flexible busbar commonly used?

The flexible busbar is widely used across energy storage systems (photovoltaic combiner boxes, grid-connected energy storage), industrial and rail transit fields (motor drives, welding machine transformers, high-speed train pantographs), and power electronics (switchgear, bus ducts, vacuum circuit breakers, frequency converters).