What Is Application of Copper Foil Flexible Busbars in Auxiliary Power Supply Field ?

Auxiliary power supplies serve as core supporting units for power electronic equipment such as rail transit converters, energy storage converters, industrial frequency converters and UPS systems. They provide stable power for equipment control circuits, cooling systems, detection components and switching elements. The safety and stability of the whole equipment heavily rely on the reliability of auxiliary power supplies. Under complex working conditions including frequent start-stop, cyclic temperature changes inside cabinets and continuous vibration from cooling fans, traditional rigid copper bars are prone to thermal stress cracking, loose bolts and local overheating. Ordinary cables suffer from messy wiring, poor heat dissipation and high stray inductance, failing to meet the design requirements of high-end auxiliary power supplies. In response, Xi'an Zipeng Technology focuses on flexible conductive connections and offers customized copper foil flexible busbars to solve pain points in power connections of auxiliary power supplies.

Copper foil flexible busbars are made by stacking multiple layers of high-purity T2 electrolytic copper foil. Both ends are integrally formed via molecular diffusion welding without solder interlayers, delivering compact and stable structure. Combining flexible deformation capacity and high-current conductivity, they are preferred connection components suitable for narrow cabinets, high-frequency working conditions and long-term operation of auxiliary power supplies. They are widely adopted in key connection positions of auxiliary power supplies: flexible transition between rectifier modules and DC busbars, power extraction between IGBT power modules and filter capacitors, output bus connection and cross-cabinet isolated wiring. The products can accurately compensate assembly tolerances and relieve deformation stress generated during equipment operation.

Compared with conventional connections, Xi'an Zipeng copper foil flexible busbars have outstanding advantages for auxiliary power supplies. Firstly, they provide excellent thermal stress compensation to offset deformation caused by alternating hot and cold cycles of power devices, stabilize contact resistance and prevent failures such as loosening and thermal burnout during long-term operation. Secondly, the integrated diffusion welding process avoids copper foil delamination. The flexible structure cushions continuous vibration and shock in vehicle-mounted and industrial equipment, perfectly adapting to high-vibration scenarios like rail transit and extending equipment service life.

Meanwhile, the stacked multi-layer structure greatly reduces stray inductance of power loops, suppresses switching voltage spikes and mitigates electromagnetic interference to optimize operating characteristics of high-frequency switching power supplies. The flat integrated structure has a larger heat dissipation area and avoids heat accumulation of cables, keeping cabinet temperature rise under control for confined high-temperature environments such as energy storage cabins and industrial electric cabinets. Customizable bending shapes and mounting holes together with flame-retardant silicone insulation cover support a wide temperature range and neat, compact wiring for new miniaturized and integrated auxiliary power supplies.

Backed by mature R&D and manufacturing systems, Xi'an Zipeng selects copper foil layers and conductor cross-sections according to customers’ current parameters, installation space and operating environments. Surface treatments including tin plating and silver plating are available. All products undergo full tests of resistance, voltage withstand and tension before delivery, and can support customers to complete type tests of complete equipment. Our flexible busbars have been widely applied to vehicle-mounted auxiliary power supplies, auxiliary power supplies for energy storage PCS and high-power industrial power supplies.

Driven by the industry trend of miniaturization, high reliability and long service life of power equipment, copper foil flexible busbars are gradually replacing traditional rigid copper bars and ordinary cables as the core power connection solution for auxiliary power supplies. Going forward, Xi'an Zipeng Technology will continuously optimize the processes of flexible conductive products, deepen the supporting business for auxiliary power supplies, and deliver efficient, stable and customized connection solutions for industry customers.

Need a samples for testing? welcome to mail: info@zpbusbar.com