High-Voltage Power Supply Flexible Copper Busbar from China Suppliers - Reliable Factory Solutions for HV Systems
Material Specifications
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Base Material: T2 high-purity copper foil (copper content ≥99.95%, conductivity ≥97% IACS), ensuring excellent electrical conductivity and thermal conductivity
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Copper Foil Thickness: 0.05 / 0.1 / 0.2mm (0.1mm as standard), optional according to HV current requirements
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Number of Layers: 20–100 layers (customized according to rated current; the more layers, the stronger the current-carrying capacity)
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Cross-Section Dimensions: Width 20–100mm, total thickness 1–10mm, flexible adjustment to fit different installation spaces
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Standard Length: 50–300mm (customizable; supports non-standard length customization according to HV equipment layout)
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Terminal Dimensions: Customized according to HV power supply equipment interface (aperture φ5–φ12mm, hole spacing accurately matched to avoid installation deviation)
Electrical Performance (HV Adaptation)
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Rated Current: 300–1500A (commonly used 600 / 800 / 1000A for HV power supply scenarios), suitable for different power levels of HV systems
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Contact Resistance: ≤40μΩ (@20℃, silver-plated terminals) — ultra-low resistance to reduce energy loss and avoid overheating
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Insulation Withstand Voltage: AC 3000V / 1min (no breakdown), effectively adapting to HV working environment and ensuring safe insulation
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Insulation Resistance: ≥500MΩ — strong insulation performance to prevent HV leakage and short circuit risks
Typical Application Scenarios (HV Power Supply)
New Energy Vehicle HV System
Motor Controller (MCU) IGBT module → drive motor three-phase terminal connection, HV battery pack confluence, OBC/DC-DC converter connection
Industrial HV Power Supply
High-power inverter, servo controller, rectifier cabinet high-current flexible connection (electrolysis, metallurgy, chemical industry and other HV scenarios)
Energy Storage HV System
Container energy storage battery cluster, energy storage converter (PCS) busbar connection, HV distribution cabinet internal connection
HV Electrical Equipment
Transformer high and low voltage side outlet, switchgear, GIS, isolating switch flexible connection
Special HV Scenarios
Rail transit HV traction system, ship HV power supply, medical equipment HV power connection
Quality Assurance
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Raw Materials: T2 high-purity copper foil, complying with GB/T 5231, ensuring HV electrical performance
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Process: Advanced polymer diffusion welding — no false welding or bubbles, ensuring stable connection under HV large current
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Factory Inspection: 100% resistance test, withstand voltage test, and dimension inspection — eliminating unqualified products for HV use
Package & Shipment
Frequently Asked Questions
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What copper material is used in your high-voltage flexible copper busbar, and why does it matter?
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We use T2 high-purity copper foil with a copper content of ≥99.95% and conductivity ≥97% IACS. This grade of copper ensures superior electrical conductivity, minimal resistive losses, and excellent thermal dissipation — all critical for reliable performance in high-voltage power supply environments.
Q
Can the dimensions and layer count of the flexible copper busbar be customized?
A
Yes. We offer full customization including width (20–100mm), total thickness (1–10mm), length (50–300mm or non-standard), copper foil thickness (0.05 / 0.1 / 0.2mm), and number of layers (20–100). Terminal hole size (φ5–φ12mm) and hole spacing can also be precisely matched to your equipment interface.
Q
What is the maximum rated current these flexible busbars can handle?
A
Our flexible copper busbars support rated currents from 300A up to 1500A. For most high-voltage power supply applications, 600A, 800A, and 1000A configurations are commonly specified. The current-carrying capacity scales with the number of copper foil layers.
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What insulation and withstand voltage standards does the product meet?
A
The flexible copper busbar passes AC 3000V / 1 minute withstand voltage testing with no breakdown, and achieves an insulation resistance of ≥500MΩ. These specifications ensure safe, reliable operation in high-voltage environments and minimize risks of leakage or short circuits.
Q
What quality control processes are applied before shipment?
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Every busbar undergoes 100% factory inspection including resistance testing, high-voltage withstand testing, and full dimensional verification. Our manufacturing process uses advanced polymer diffusion welding to eliminate false welds and air bubbles, ensuring structural and electrical integrity under high-current conditions.
Q
Which industries and applications are these high-voltage flexible copper busbars suitable for?
A
These busbars are widely used across new energy vehicles (MCU, IGBT modules, battery packs, OBC/DC-DC converters), industrial high-voltage power supplies (inverters, servo controllers, rectifier cabinets), energy storage systems (PCS, battery clusters), HV electrical equipment (transformers, switchgear, GIS), and special sectors such as rail transit, marine power, and medical HV systems.