Laminated Copper Foil Flexible Busbar For Low-Voltage High Current Distribution Cabinets

This laminated copper foil flexible busbar (soft copper connector) is specially designed for 0.4kV low-voltage high-current switchgear systems, including GCK/GCS/MNS drawer cabinets, transformer low-voltage connections, capacitor compensation cabinets and rectifier cabinets.

Made of stacked T2 pure copper foils with polymer diffusion welding on two terminals, the middle multi-layer foil section retains high flexibility. It offsets thermal expansion stress and equipment vibration, fundamentally solving common failures like loose bolts, abnormal temperature rise and contact burnout caused by rigid copper bars. Multiple plating and insulation options support customized adaptation to indoor, humid, dust-prone and heavy-load working conditions.

Catalog Contact us

Product Details

1. Core Raw Material

Conductive Material: T2 oxygen-free pure copper foil, Cu ≥99.95%, high conductivity, low DC resistance, effectively reduce skin effect loss under large current
Single Foil Thickness: 0.05mm / 0.1mm / 0.2mm customizable
Surface Plating Options

Tin plating (3–8μm): Standard indoor cabinet, cost-effective anti-oxidation
Nickel plating (5–10μm): Moist, coastal and dust-intensive environments, superior salt spray resistance
Silver plating (2–5μm): Heavy current main circuit, ultra-low contact resistance, minimal temperature rise

2. Core Production Technology — Polymer Diffusion Welding

Only two terminal areas are fused under high temperature (500–620℃) and constant pressure (10–30MPa). Copper atoms interpenetrate to form an integrated solid terminal without solder, voids or gaps.

Tensile strength reaches over 90% of copper base material
100,000 bending fatigue cycles without delamination or cracking
Stable contact pressure during long-term vibration operation

3. Key Advantages for Low-Voltage Cabinet Use

1. Vibration & Thermal Stress Compensation

Eliminate rigid connection stress from transformer and contactor vibration; avoid bolt loosening and local overheating

2. Higher Current Carrying & Lower Temperature Rise

Multi-layer stacked structure expands heat dissipation area, 30% higher ampacity than solid copper bar with same cross-section, effectively reduce cabinet internal heat accumulation

3. Flexible On-site Installation

Bendable flexible segment adapts narrow and irregular cabinet layout, greatly reduce assembly difficulty and rework rate

4. Long Service Life

Far better anti-fatigue performance than braided copper belts, stable performance for 24h continuous industrial operation

5. Full Customization Support

Adjust width, length, foil layers, hole size, plating and insulation according to cabinet current parameters and drawings

4. Typical Application Scenarios

0.4kV low voltage incoming & outgoing cabinets
GCK / GCS / MNS drawer type switchgear
Transformer low-voltage side flexible connection
Capacitor compensation cabinet
High-power industrial rectifier cabinet
Busbar section transition connection

4. Why choose our busbar:

Free technical calculation & solution design based on customer rated current
Fast prototype samples within 24–48 hours
Mass production delivery in 7–10 days for customized orders
Long-term after-sales warranty, technical guidance for overseas cabinet manufacturers

Packing & Shipment

Inner packing: Anti-static plastic bag for single product
Outer packing: Standard export carton, wooden case for extra large heavy busbars
Shipping: Sea freight, air freight, international express (DHL/FedEx/TNT) support