High-Quality Copper Foil Flexible Busbar from China Suppliers & Factory for High Current Applications
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
New Energy Vehicles (EV)
Battery module/pack connections, motor inverter, 800V high-voltage platforms
Energy Storage Systems (ESS)
Battery rack → PCS/inverter connections, large-scale energy storage cabinets
Power & Industrial
Generators, transformers, high-voltage switchgear, large rectifiers, electrolysis equipment
Rail Transit
Locomotive power distribution, metro vehicle electrical systems
Data Centers & UPS
High-power power distribution, server room busbar connections
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 specifications applied if not explicitly specified
03
Hole Details
Quantity, diameter, and position (engineering drawing preferred)
04
Surface Treatment
Bare / Tin-Plated / Nickel-Plated / Silver-Plated
05
Insulation
Type (Heat Shrink Tubing / PVC Dipping) & desired color
06
Current Rating & Environment
Operating current and temperature for technical matching
Why Choose Our Copper Foil Flexible Busbar?
Professional Customization
10+ years of dedicated R&D expertise for high-current flexible connections.
Stable Performance
Low, consistent contact resistance providing dependable long-term reliability.
Technical Support
Complimentary design review, optimization, and technical solution consultation.
Lead Time
Fast manufacturing cycle and expedited dispatch (7-8 working days).
Package & Shipment
Frequently Asked Questions (FAQ)
Q1: What is the advantage of a copper foil flexible busbar over a rigid busbar?
Copper foil flexible busbars absorb mechanical vibration, compensate for thermal expansion and contraction, and simplify installation in compact or misaligned equipment layouts while maintaining high current conductivity.
Q2: What insulation materials and voltage ratings can you provide?
We supply high-grade PVC dipping, heat-shrink tubing (PE/PVDF), and silicone insulation with dielectric withstand voltages up to DC 4000V/1min and continuous working temperatures up to 150°C.
Q3: Can you fabricate custom busbars from 2D/3D drawings?
Yes. Our engineering team can manufacture strictly according to your CAD drawings (DWG, DXF, STEP, PDF), including custom hole patterns, stepped widths, and multi-layer configurations.
Q4: Which surface plating option should I choose?
Tin plating offers cost-effective anti-oxidation and solderability; nickel plating provides superior wear and corrosion resistance; silver plating delivers the lowest contact resistance for demanding ultra-high-frequency or high-current interfaces.
Q5: What is the typical lead time for custom production orders?
Standard custom prototypes and production batches typically take 7 to 8 working days. Urgent project requests can also be accommodated upon technical review.