GRL flexible copper busbar 0.10mm copper foil soft connection

Flexible Copper Busbar Overview

What is a Flexible Copper Busbar?

A flexible copper busbar is a type of electrical conductor, distinct from its traditional rigid counterparts, made from high conductivity copper.

Its design incorporates a series of thin copper laminates in a flat, flexible arrangement, allowing for much greater flexibility and adaptability in installation and use.

This innovative structure enables the busbar to bend, twist, and flex, accommodating a wide range of configurations and applications while maintaining excellent electrical conductivity and efficiency.

Flexible Copper Busbar Technical Parameter

• Material

T2 copper foil, copper content >99.95% Single

• Piece thickness

0.03mm / 0.05mm / 0.10mm(regular) /

0.20mm / 0.30mm / 0.40mm / 0.50mm

• Surface treatment

bare copper, tin plating, nickel plating

• silver plating Cross-sectional area

1.5mm2-5000mm

• When placing an order, please specify the following values:

Length (L)x Width (W)x Thickness (T)

Product shape and hole type

Aperture(d)

Single piece thickness (conventional 0.10mm)

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Flexible Copper Busbar Structure and Application

The flexible copper busbar is made of multiple layers of highly flexible flat thin copper sheets, and the outer layer is made of extrusion-wrapped heating ground layer. The insulation layer currently includes special polyurethane (PVC) and thermoplastic elastomer (TPE). Two materials.

TPE has low smoke and halogen-free properties. The insulation is black. Since the copper conductor can slide freely within the insulation layer, the non-threaded soft busbar has eyeless bending and torsion characteristics.

At the same time, the multi-layer flat conductor structure of the explosion-proof flexible copper busbar enables the same conductor cross-sectional area to carry a larger passing current, thus reducing the amount of conductor material, which not only reduces the weight, but also saves space.

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Flexible Copper Busbar Features

The core appeal of flexible copper busbars is their unique blend of flexibility and performance.

Unlike rigid busbars, which require precise alignment and can be cumbersome to install in complex configurations, flexible copper busbars are easy to handle and install in tight spaces.

This adaptability does not come at the expense of electrical performance; similar to rigid busbars, flexible copper busbars provide superior current carrying capabilities and efficient power distribution.

Not only that, the flexible copper busbar has good wear resistance and resistance to substances such as oil, solvents and chemicals: PVC insulation material can withstand high temperatures up to 80 degrees Celsius.

Advantages of flexible copper busbar

1、Enhanced Design Flexibility: The ability to bend and flex allows for creative and efficient use of space within electrical systems. Designers can work around obstacles and optimize layouts, reducing the need for custom connectors and complicated wiring schemes.

2、Simplified Installation and Maintenance: The inherent flexibility significantly simplifies the installation process, making it faster and less labor-intensive. Maintenance and upgrades are also more straightforward, as the flexible busbar can be easily adjusted or reconfigured.

3、Improved Reliability and Safety: By reducing the number of electrical connections and eliminating the need for additional joining components, flexible copper busbars enhance the reliability of the electrical system.

This streamlined design minimizes potential failure points and improves overall safety.

4、Superior Electrical Performance: Despite their flexible nature, these busbars maintain excellent electrical conductivity and efficiency.

They efficiently handle high currents, reducing energy losses and improving the overall performance of the power distribution system.

5、Vibration Resistance: In environments where machinery or equipment may cause vibrations, flexible copper busbars demonstrate superior performance by absorbing and withstanding these forces, ensuring a stable and uninterrupted power supply.

What are the different types of copper busbars?

Standard Copper Busbar

The most common type, typically a flat copper bar. Due to its excellent conductivity and ability to handle high current loads, it is widely used in distribution boards, power distribution devices, and substations. Its large surface area provides efficient heat dissipation, making it the first choice for high- and low-voltage power systems. They are often used in industrial and commercial electrical systems, where robustness and efficiency are critical.

Custom Copper Busbar

The shape and length of custom copper busbars can be tailored to meet specific requirements and bent to fit particular installation environments. These busbars offer design flexibility and are typically used in complex electrical systems where optimized space utilization and reliable electrical connections are required.

Flexible Laminated Busbar

These busbars are made from multiple layers of copper. These connectors offer excellent flexibility and conductivity, used in high-current applications where power density and electrical efficiency are critical. The laminated structure allows for better heat dissipation and reduced inductance, making it suitable for power converters, renewable energy systems, and electric vehicles (EVs).

Stranded Copper Wire

Made from multiple copper wires twisted together, stranded busbars offer greater flexibility and mechanical strength compared to solid busbars. These are typically used in mobile electrical equipment and systems where connections need to withstand mechanical stress, vibration, or repeated bending.

Braided Copper Busbar

Composed of braided copper wires, this type offers excellent flexibility and vibration resistance. Braided busbars are used for grounding, shielding, and flexible connection applications, especially in electrical systems that require frequent movement or mechanical flexibility.

Tin-Plated Copper Busbar

Tin plating prevents oxidation and corrosion, making it suitable for harsh environments such as marine or outdoor applications. The tin coating also reduces the risk of contact resistance, improving the overall performance of electrical systems, particularly in high-humidity conditions.

Insulated Copper Busbar

These busbars are coated with an insulating layer to prevent accidental contact and improve safety. They are typically used in applications with high safety standards, such as switchgear and control panels. The insulation also helps reduce electromagnetic interference (EMI).

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