Flexible Busbars
High-performance laminated copper connectors engineered for reliable power transmission in demanding applications. Our flexible busbars provide the perfect balance of electrical conductivity, mechanical flexibility, and thermal performance.
What Are Flexible Busbars?
Flexible busbars, also known as laminated busbars or flexible copper connectors, are electrical conductors made from multiple thin copper foils or strips laminated together. This construction provides the high current-carrying capacity of solid copper with added flexibility for dynamic connections.
Unlike rigid busbars, flexible busbars can absorb mechanical stresses from thermal expansion, vibration, and installation tolerances. This makes them ideal for connections between fixed and moving components, or where precise alignment is difficult to achieve.
Our flexible busbars are manufactured using high-purity electrolytic copper with optional insulation and surface treatments to meet specific application requirements.
Construction
- Multiple thin copper laminations (0.1-0.5mm each)
- Solid copper terminal ends for connections
- Optional insulation between laminations
- Surface plating for corrosion protection
- Custom bend profiles and lengths
- Drilled or threaded terminal options
Applications
Switchgear & Transformers
Flexible connections for power distribution equipment, compensating for thermal expansion and vibration.
- Thermal expansion compensation
- Vibration isolation
- Easy installation
- Long service life
EV Battery Packs
High-current connections for electric vehicle battery modules and packs with optimized space efficiency.
- High current capacity
- Compact design
- Thermal management
- Weight optimization
Key Advantages
High Current Capacity
Multiple copper laminations provide excellent current-carrying capability with minimal resistance.
Flexibility
Accommodates thermal expansion, vibration, and misalignment between connection points.
Low Inductance
Laminated construction minimizes inductance for improved electrical performance.
Space Efficient
Compact profile allows installation in tight spaces where rigid busbars cannot fit.
Thermal Performance
Excellent heat dissipation through multiple thin copper layers with large surface area.
Custom Solutions
Manufactured to customer specifications for optimal fit and performance.
Technical Specifications
| Conductor Material | Electrolytic Copper (ETP) |
| Purity | 99.9%+ Cu |
| Lamination Thickness | 0.1 - 0.5 mm |
| Number of Laminations | 10 - 200+ layers |
| Current Rating | Up to 10,000 A |
| Insulation Options | Polyolefin heat shrink sleeves |
| Terminal Types | Drilled holes, Threaded studs, Custom |
| Plating Options | Tin, Nickel, Silver |
Industries Served
Material Options
Custom Flexible Busbar Solutions
Every application is unique. Contact our engineering team to discuss your specific requirements and receive a custom solution designed for your exact specifications.
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