As the name suggests, a soft copper busbar is soft. It's made from copper material that has undergone special processing to impart flexibility. Its structure is relatively simple, and its primary component is copper. Copper's excellent conductivity effectively reduces electrical resistance and minimizes energy loss during transmission.
Compared to ordinary copper busbars, soft copper busbars undergo special processing, such as using multiple layers of copper foil or braided fine wires. This allows them to bend and deform to a certain extent!
A common method for making soft copper busbars is to stack multiple layers of copper foil. These layers are typically very thin, typically between 0.05 and 0.3 mm thick, with the number of layers determined by factors such as the required current carrying capacity and mechanical strength. They are then bonded together using specialized welding or lamination processes. This resulting soft copper busbar maintains excellent conductivity while maintaining a certain degree of flexibility, making it suitable for electrical connections requiring bends or irregular shapes. The surface of this flexible connector is relatively flat, and it also exhibits good flexibility in planar directions. Another manufacturing method involves braiding multiple strands of fine copper wire into a braid-like shape. The wire diameter is typically around 0.1-0.5mm. This braided structure provides excellent stretchability and flexibility in all directions; its overall shape can be stretched and twisted to varying degrees depending on actual needs. This type of flexible copper busbar is often used to connect electrical equipment that is subject to frequent movement or vibration, such as the battery system in electric vehicles.
The term "copper flexible connector" emphasizes its connection function! It is a complete connection device. In addition to the flexible copper busbar, it also includes connecting components, such as the terminals at each end. These terminals can take various forms, such as copper bolt holes and crimp terminals. Overall, a copper flexible connector is a combination of a flexible copper busbar and terminals, used to connect two or more electrical devices.
Next, we will detail the three major application areas of copper flexible connectors.
1. Power Industry
In substations, copper flexible connectors are used to connect transformers, switchgear, busbars, and other equipment. For example, copper flexible connectors are used between the low-voltage outgoing line of a transformer and the switchgear to accommodate the slight vibrations and thermal expansion and contraction generated during transformer operation. Furthermore, between the moving and static contacts of a high-voltage switch, copper flexible connectors effectively transmit current and cushion the impact of contact closing and opening.
Furthermore, copper flexible connectors serve as both a connection and a buffer between the outgoing line of a generator and the distribution cabinet. Generators generate vibration during operation, and copper flexible connectors ensure stable current transmission, prevent loose connections, and ensure safe operation of the power system.
II. New Energy Sector
Electric vehicle battery packs are composed of multiple battery modules. Copper flexible connectors connect these battery modules, accommodating thermal expansion and contraction during charging and discharging, as well as vibration during vehicle operation.
Copper flexible connectors are also used between the motor controller and the motor to ensure efficient power transmission and adapt to the motor's operating environment.
Secondly, in solar photovoltaic power generation systems, copper flexible connectors are used to connect equipment such as photovoltaic panels, combiner boxes, and inverters. Photovoltaic modules deform under varying lighting and temperature conditions. Copper flexible connectors adapt to these changes, ensuring stable energy collection and transmission.
III. Electronic Equipment
In communications base stations, copper flexible connectors are used to connect components such as circuit boards, power amplifiers, and antenna feeders. The compact interior of communications equipment can lead to relative displacement between components. Copper flexible connectors adapt to this displacement while maintaining electrical conductivity, ensuring stable signal transmission.
In large servers, copper flexible connectors enable efficient electrical connections between motherboards and expansion cards, power modules and motherboards, and other components within limited space. Furthermore, heat generated during server operation causes components to expand. Copper flexible connectors adapt to these changes, preventing overheating or loosening of connection points.
The company has a cluster of leading copper processing production lines in China, including:
German imported precision copper tube production line (annual output of 30,000 tons)
Japanese technology copper foil rolling line (thinnest up to 6μm)
Fully automatic copper bar continuous extrusion line
Intelligent copper sheet and strip finishing mill unit
Digitalized control and management of the whole production process is realized through MES system, and the dimensional accuracy of the products can reach ±0.01mm.
