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Specialized Copper Foil Flexible Connectors for Power Transformers - China Suppliers & Factory Solutions

Our busbars are expertly engineered for power transformers, making them ideal for both high and low voltage side outgoing lines, neutral point connections, and busbar transitions. Designed to buffer vibrations and alleviate stress from thermal expansion and contraction, these busbars ensure the long-term stability and reliable operation of transformers.

As a leading manufacturer in China, we offer customizable solutions based on transformer models, installation dimensions, and specific current and voltage requirements. Our flexible busbars, made from high-quality copper foil, can be tailored with a thickness ranging from 0.05mm to 0.3mm, and the number of layers, length, and end sizes can also be adjusted to meet your needs.

We pride ourselves on being a trusted supplier with the capability to fulfill custom orders based on detailed drawings or samples. With controllable delivery times and precise alignment with various connection requirements for power transformers, you can rely on our factory for all your busbar solutions.

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Product Details

The Core Advantages

Strong Special Adaptability

Precisely matched with oil-immersed and dry-type power transformers, covering voltage levels of 10kV–1100kV and current levels of 1kA–50kA.

High-Quality Material

Adopting T2 high-purity copper foil (copper content ≥99.9%), with high conductivity, low resistance and low heat generation.

Mature & Durable Craftsmanship

Adopting polymer diffusion welding/molecular welding process, no solder residue, extending service life to ≥25 years.

Outstanding Core Functions

Effectively buffers vibration, releases stress caused by thermal expansion, and compensates for installation errors.

Copper Foil Flexible Connector for Power Transformer

Copper Foil Flexible Connector Detail View

Flexible Copper Busbar Connector Product

Technical Specifications

Parameter Name	Specification Range	Description (Special Adaptation)
Material	T2 Copper Foil	Copper content ≥99.9%, conductivity ≥98%IACS. Supporting flexible busbar customization.
Copper Foil Thickness	0.05mm, 0.1mm, 0.2mm, 0.3mm	Layers can be laminated and increased for high current according to needs.
Voltage Level	10kV–1100kV	Covers all specifications of distribution and power transformers.
Current Level	1kA–50kA	Customizable for high/low voltage outgoing lines and neutral points.
Surface Treatment	Bare Copper, Tin/Silver Plating	Tin plating for anti-oxidation; silver plating for low contact resistance.
Welding Process	Polymer Diffusion/Molecular Welding	No welding slag, firm bonding, tensile strength ≥120MPa.
Insulation Protection	PVC/Silicone/Fluoroplastic	Leakage-proof and corrosion-proof, suitable for outdoor/humid environments.
Service Life	≥25 Years	Meets the service life standard of power transformers.

Application Scenarios

This product is specially designed for power transformers, mainly applied in the following scenarios:

◈ Connection of high and low voltage side outgoing lines of power transformers to realize conductive transition

◈ Neutral point connection of transformers to ensure grounding safety

◈ Conductive transition between transformers, bus ducts and power distribution cabinets

◈ Internal conductive connection of oil-immersed and dry-type power transformers

◈ Power transformer renovation and expansion projects in power substations

◈ Transformer-related conductive connection scenarios in power plants and power grid projects

Product Details

Copper Foil Details

High-purity T2 copper foil is selected, with flat surface, no oxidation and no scratches, stable conductive performance.

Welding Details

Supported by diffusion welding process, the terminal is firmly welded, tensile and vibration-resistant.

Surface Treatment Details

The tin plating layer is uniform, effectively preventing copper foil oxidation; the silver plating layer is bright for large current.

Insulation Details

The insulation sleeve fits closely, temperature-resistant, fireproof and leakage-proof, complying with safety standards.

Dimensional Accuracy

Processed strictly according to drawings, dimensional error ≤±0.1mm, adapting to transformer installation size.

Package & Shipment

Copper Foil Flexible Connector Packaging and Shipping

Frequently Asked Questions

What voltage and current levels does this copper foil flexible connector support?

This product supports voltage levels ranging from 10kV to 1100kV and current levels from 1kA to 50kA, making it suitable for both distribution and high-voltage power transformers. Custom specifications are also available for specific project requirements.

What material is used in the copper foil flexible connector?

The connector uses T2 high-purity copper foil with a copper content of ≥99.9% and conductivity ≥98% IACS. Available thicknesses include 0.05mm, 0.1mm, 0.2mm, and 0.3mm, with multi-layer lamination options for high-current applications.

What welding process is used and why does it matter?

We use polymer diffusion welding (molecular welding) technology. This process produces no welding slag, ensures firm terminal bonding with tensile strength ≥120MPa, and results in a longer, more reliable service life compared to traditional soldering methods.

What surface treatment options are available?

Three surface treatment options are available: bare copper, tin plating, and silver plating. Tin plating provides effective anti-oxidation protection for standard environments, while silver plating offers lower contact resistance and is recommended for high-current applications.

Is this product suitable for outdoor or humid environments?

Yes. The insulation sleeve is available in PVC, silicone, or fluoroplastic materials, all of which are leakage-proof and corrosion-resistant. The product is designed to perform reliably in outdoor, humid, and chemically challenging environments.

Can the dimensions be customized to fit specific transformer installations?

Absolutely. All products are manufactured strictly according to customer-provided drawings, with a dimensional tolerance of ≤±0.1mm. Custom sizes are available for high/low voltage outgoing lines, neutral point connections, and various transformer installation configurations.