Insulated Custom Flexible Bus Bar - Flat Copper Busbar for Battery Applications
Flexible busbars are manufactured by brazing copper foil parts together, utilizing 99.9% pure copper content. This construction provides excellent conductivity with minimal impurities, while laminated copper busbars offer increased current carrying surface area.
Copper Foil Specifications
Thickness range: 0.05mm to 0.3mm. Contact surfaces can be tinned or silvered according to user requirements. Current capacity is calculated based on 1 square knitting belt with effective load current of 4A. Copper conductors with different sectional areas feature varying parameters. Larger areas can be multi-layered or configured as sets.
Material Standards
| Standard | Specification |
|---|
| GB | T2 Copper with Min. 99.9% |
| DIN | E-Cu58 (Number: 2.0065) |
| EN | Cu-ETP (Number: CW004A) |
| ISO | Cu-ETP |
| UNS | C11000 |
| JIS | C1100 |
| BS | C101 |
| Other | Custom materials available upon request |
Technical Specifications
- Resistance: 0.00001Ω
- Conductivity: 57%
- Copper Foil Single Layer Thickness: 0.1/0.2/0.3/0.5/1.0mm (suitable thickness advised based on bus bar structure)
- Insulation Material: PVC Dipping Coating with excellent performance, suitable for special shaped bus bars, resistant to breakage during repeated bending
- Insulation Performance: PE and PVC both perform well, with PVC dipping superior to PE heat shrink tubes
- Flame Retardant/Fire Resistance: UL94-V-0 or customized to your requirements
- Surface Plating: Nickel, tin, or silver plated options available
- Plating Thickness: Normally 3um to 12um or customized
- Salt Spray Testing: Nickel withstands 240 hours in neutral environment (silver and tin have lower resistance)
- Bending Testing: Withstands 10,000 bends at 15 radian angle without breakage or fracture
- Operating Temperature: -45°C to +150°C
- Copper Foil Tensile Strength: ≥500N
Leakage Testing Performance
PVC Dipping Sleeves testing results:
- 3500VDC for 30s at 1.5mm thickness: Leakage 0.025 MA
- 5000 VAC for 30s to 60s at 1.8mm to 2.0mm thickness: Leakage 0.065 MA
We provide customized solutions based on your specific working voltage requirements.
Temperature Rise Testing
Testing varies based on flexible busbar cross-sectional area. We provide complete temperature rising test reports before delivery upon request.
Ordering Information
- Quote Time: 1-3 working days after receiving your inquiry
- Sample/Trial Order Delivery: 5-15 working days depending on bus bar structure and manufacturing process
Quality & Environmental Certifications
- Quality Management: Auto Industry IATF 16949
- Eco-friendly: ROHS, REACH compliant
Conductor Options
Conductor: Flexible Bare annealed copper wire
Insulation: Copper
Jacket Colors: Black, Orange, Red, Yellow, Blue (single & double insulated)
SQ MM sizes (European style): Customizable
AWG sizes (North American style): Customizable
Temperature Range: Customizable
Silicone Insulated Option
Conductor: Flexible Bare annealed copper wire
Insulation: Silicone
Jacket Colors: Black, Orange, Red, Yellow, Blue (single & double insulated)
SQ MM sizes: 4 sq mm to 240 sq mm
AWG sizes: 0AWG-10AWG
Temperature Range: -60°C to 200°C
Manufacturer Profile
Linke Cable Technology Co., Ltd is a leading Chinese cable manufacturer with over 10 years of experience in R&D, production, and marketing of wire and cable products. We specialize in providing custom cable solutions worldwide, including EV charging cables, medical cables, silicone cables, spring cables, braided cables, towlobe cables, UL wires, and automotive cables.
Our engineering-focused approach ensures we develop superior cables that enhance quality and performance for our customers.
Certifications
UL1007, UL1185, UL1672, UL10070, UL10483, UL1015, UL1569, UL10012, UL10269 (Single conductor, thermoplastic insulation)
UL2095, UL2129, UL2468, UL2586, UL2725, UL20233, UL20280, UL20963, UL2103, UL2463, UL2517, UL2587, UL2835, UL20276, UL20549, UL21198, 2104, UL2464, UL2576, UL2661, UL2919, UL20279, UL20886, UL21664
ISO9001 and ISO13485, TS16949
CNR- Appliance Wiring Material
Frequently Asked Questions
Are you a manufacturer or trading company?
We are a professional manufacturer that controls your order from beginning to end. We welcome visits and provide pickup service in Shenzhen.
How can I get a sample to test your quality?
Samples are free for customers. New clients are expected to pay for courier costs.
What's your Minimum Order Quantity?
Normally 100m. However, due to cable weight, we recommend ordering suitable quantities to avoid high freight costs. Sea transportation is the most economical option.
Can I get a discount?
Discounts depend on order quantity. We can offer discounts and cover freight costs for larger orders. Please contact us for details.
Does your company accept OEM production?
Yes, we can print your company name and even customize quality cards to promote your brand.
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