Copper Foil Flexible Busbar 04

00-Manufacturing process of copper foil flexible busbar-PVC Dipping Coating

Ø  Raw material selection 01: C11000-H00, C11000-H02(T2/Cu-ETP) 0.1mm/0.2mm foil

Ø  Raw material selection 02: C10200-H00, C10200-H02(Tu2/Cu-OF) 0.1mm/0.2mm foil

Ø  Die cutting: Die cutting to get the foil material with needed shape

Ø  Welding: The two ends of the copper foil will be fused and welded together by the high current and high temperature of the diffusion welding

Ø  Stamping/CNC machining: Stamping or CNC machining to remove redundant material

Ø  Electroplating: Typically, both ends will be soldered with Ni200/N6 nickel foil,If really need electroplating, Just electroplate the rigid area

Ø  Insulation treatment: Usually we will add heat shrink tube to flexible area for normal shape parts,And do PVC dip coating to some irregular parts

01-Introduction to Copper Foil flexible busbar

Ø  Copper foil flexible busbar is an electrical connection part composed of multiple layers of 0.1mm or 0.2mm thickness copper foil

Ø  It includes two different areas: rigid area and flexible area. The rigid area is formed by molecular diffusion welding; The soft area was not welded during the manufacturing process to maintain flexibility,providing tolerance compensation for subsequent installation or adaptability to variation

Ø  Copper foil flexible busbar Connects battery cells or other modules in the pack through laser welding or nut/bolt connection

02-Future development direction

Ø  Improving flexibility and corrosion resistance: continuous exploration of new materials and optimization of production processes are needed

Ø  Conductivity and heat dissipation performance: With the increasing requirements for range and charging speed of new energy vehicles, the energy density and power density of battery packs are also increasing, which puts higher requirement on the conductivity, heat dissipation, and temperature resistance of copper foil flexible busbar

03-Advantages of copper foil flexible busbar

Ø  Flexibility: copper foil has good flexibility and can be bent and folded as needed to meet the connection needs of various shapes and sizes

Ø  Excellent conductivity:copper foil has good conductivity, low resistivity and thermal resistance, which can effectively reduce energy loss and temperature rise,and improve the efficiency and stability of electrical equipment

Ø  Safe and reliable:copper foil flexible connections have excellent electrical insulation and corrosion resistance, which can effectively prevent leakage and fire accidents. Which can maintain good performance stability even in low and high temperature environments

Ø  Non magnetic: copper foil flexible busbar is non-magnetic and will not cause electromagnetic interference to surrounding electronic devices

Ø  Easy to recycle: copper foil is a recyclable material that meets environmental requirements

04-Copper foil flexible busbar compared to aluminum foil flexible busbar-Advantages

Ø  Excellent conductivity: Copper has better conductivity than aluminum, it is suitable for high current transmission and high-power applications

Ø  High stability: maintaining stable conductivity and long service life

Ø  High resistance to compression: can bend and collide freely

Ø  Good flame retardancy: Excellent flame retardancy

Ø  Better heat dissipation performance

05-Copper foil flexible busbar compared to aluminum foil flexible busbar-Disadvantages

Ø  High cost: The price of copper is relatively high

Ø  Heavy Weight: Copper has a high density, resulting in an overall increase in weight

Ø  High manufacturing costs: the price of copper diffusion welding machines is higher than aluminum diffusion welding machines

06-Choose Aluminum foil flexible busbar or Copper foil flexible busbar?

Ø To choose copper foil flexible busbar for high temperature, high pressure, and high load scenario, and aluminum foil flexible busbar for light weight and cost control

Ø The initial investment for Copper foil flexible busbar is relatively high, but their long service life and low maintenance costs make overall economy relatively ideal. In situations where high reliability and low failure rates are required, the return on investment of copper foil flexible busbar is higher