Aluminium Foil Flexible Busbar 01

00-Manufacturing process of aluminum foil flexible busbar-Weld Nickel Foil or Nickel Plating

Ø Raw material selection: Al1060-O or Al1060-24 0.1mm/0.2mm aluminum foil

Ø Die cutting: Die cutting to get the needed shape

Ø Welding: The two ends of the aluminum foil are 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

01-Introduction to Aluminum Foil flexible busbar

Ø Aluminum foil flexible busbar is a electrical connection parts composed of multiple layers of 0.1mm or 0.2mm thickness aluminum foil, The thickness can be 0.4mm-5mm 

Ø Which 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 Connect battery cells or other modules in the battery pack through laser welding or nut/bolt connection

02-Challenges and Solutions of Aluminum Foil flexible busbar

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 demands on the conductivity and heat dissipation performance of aluminum foil flexible busbar

03-Advantages of aluminum foil flexible busbar

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

Ø The product is lighter, which can reduce the weight of battery modules and improve the convenience of equipment transportation and installation

Ø Excellent conductivity: Aluminum 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: Aluminum 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: Aluminum foil flexible busbar is non-magnetic and will not cause electromagnetic interference to surrounding electronic devices

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

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

Ø Low cost: The price of aluminum is relatively low

Ø Light weight: Aluminum has a lower density, which can significantly reduce overall weight and facilitate light weight design

Ø High cost-effectiveness of heat dissipation: Although copper has better heat dissipation performance

Ø But in terms of cost calculation, the cost of copper is often more than 400% higher than that of aluminum

Ø Strong antioxidation capacity: Aluminum surface is easy to form oxide film, which has a certain self-protection effect

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

Ø Poor conductivity: Although aluminum has lower conductivity than copper

Ø Low hardness: Aluminum has a low hardness and is easy to deform, especially under high temperature or high stress conditions

Ø High coefficient of thermal expansion -23.2 × 10 ^ -6/K:  which can easily lead to an increase in contact resistance and may pose a safety hazard

Ø Limited fatigue life, unable to withstand excessive bending or vibration

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 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 the 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 usually higher