Brief introduction about copper laminated flexible connectors

Normally the standard type copper laminated flexible connectors are welded at both sides, while on your request, we can process it with ferrules which are solderless pressed.

Copper laminated flexible connectors with ferrules are also called copper foil soft connection, made of 0.05~0.5 copper foil. Because it is often used for connection on high-current equipment, it is also called high-current copper foil soft connection or Laminated Flexible Busbar.

It is a kind of flexible connection to compensate the deformation and vibration deformation caused by temperature change.

The contact area of the copper foil flexible laminated busbar connectors or the whole connectors can be plated with tin, nickle or silver. The laminated copper flexible connectors with plating have better resistance to oxidation and corrosion.

The production process of copper laminated flexible connectors with ferrules

The laminated copper flexible connectors is formed by two technologies.

The first is to press the 0.05mm–0.5mm thick copper foil laminate together partly, then adopt macromolecule diffusion welding technology. Finally, it is formed by argon welding with high current heating.

The second is to press 0.05mm – 0.5mm thick copper foil together, using silver based brazing material and flat copper block butt welding forming.

Each copper strip of the copper laminated flexible connectors with ferrules is cut by CNC punching and cutting machine tools. This can ensure that the difference between each piece of copper strip is balanced, the accuracy can reach 0.0001mm, and there is no extrusion between each piece due to uneven feeding, fully ensure that the expansion of soft connection is not limited.

Materials

Strips

  • Tin-plated C11000 ETP copper as per ASTM B33
  • Silver-plated C11000 ETP copper as per ASTM B298
  • Nickel-plated C11000 ETP copper according to ASTM B355
  • Bare C11000 ETP copper as per ASTM B152
  • Aluminum alloy 1350 as per ASTM B209

Specifications we offer for our Copper Laminated Flexible Connectors

  1. High Flexibility & Conductivity ETP Grade Copper (Cu) with a minimum copper content of 99.90% or Aluminium (Al)
  2. Resistivity: 0.01724 Ω /mm2 at 20 °C
  3. Conductivity (IACS at 20 °C ): Based on Material Thickness, ranges from 97.00% – 99.25%
  4. Cross-sectional area: 25mm2 to 6000+ mm2
  5. Insulation coating available on request
  6. Contact areas are assembled solderless, pressed copper connectors bare and on request tin (Sn) or silver (Ag) coated

We also available custom sizes.

Dimensions

  • Thickness of connecting pad up to 3″
  • Total connector length up to 72″
  • Width of connecting pad up to 10″
  • Mounting holes as per NEMA standards 

Current capacity

100 to 7,500 amperes, according to design specifications.

Laminated copper flexible connectors with insulation

On your request, the laminated copper foil connectors can be insulated with PVC heat-shrinkable tube or PVC dip coating.

Both PVC heat-shrinkable tube and PVC dip coating make the laminated copper foil connectors with better resistance to oxidation and corrosion, thus the insulation requirements of electrical parts is satisfied.

The flexibility and abrasion performance of PVC dip coating are better than those of heat-shrinkable tube, which can guarantee the completeness of the insulation of flexible laminated copper connectors in abnormal shape.

Application of no plating copper laminated flexible connector

The no plating flexible copper foil laminated connectors are mainly used for high and low voltage electrical appliances, vacuum electrical appliances, high and low voltage switchgear, welding equipment, silicon rectifier equipment, cable bridge grounding, closing busbar trough, transformer device, car, electric locomotive, industrial furnace, mine explosion-proof electrical appliances, generator set, carbon brush wire soft connection and busbar connection.

The advantages of copper laminated flexible connectors with ferrules

Flexible copper foil laminated connectors with ferrules is commonly used for industrial purposes as flexible expansion joints for connecting the bus bars in different applications. They are made by stacking several foils of electrolytic copper which may be strips with riveted or welded contact areas. Once they are stacked together, they are applied high current and pressure. 

  1. The surface area of the conductor is enlarged to increase the conductivity.
  2. Reduce stress damage to power supply facilities,prolong service life, and avoid maintenance.
  3. adjust equipment installation error to improve installation efficiency.
  4. Good heat dissipation, auxiliary cooling effect.
  5. It can avoid the operation accidents caused by earthquake and displacement.
  6. It makes the conductive connection between high current equipment more convenient, reliable and safe, and protects the associated equipment from external force.
  7. Easy installation, high electrical rate, energy saving, low connection resistance, good electrical conductivity, strong anti fatigue ability, long service life and maintenance free.