Explore Our Laminated Copper Busbars
High-Precision Laminated Copper Busbars & Shunts are engineered from multi-layered micro-foils to deliver seamless spatial flexibility, absorb thermal expansion, and maximize power density in confined cabinet layouts.
Molecular Diffusion Welded BusbarsBest for: High-current transformer connections, switchgears, and industrial electroplating equipment. Feature: The foil ends are solid-bonded via high-temperature molecular diffusion welding without welding flux, creating a single solid copper block for ultra-low resistance. |
Insulated Flexible Busbars for EV & ESSBest for: Electric vehicle battery packs, Energy Storage Systems, and compact power inverters. Feature: Coated with high-dielectric insulation sleeves, designed to withstand high voltages while offering excellent multi-angle bending in confined layouts. |
Braided & Laminated Hybrid ShuntsBest for: Extreme-vibration environments requiring deep expansion joints and massive cross-sectional current capabilities. Feature: Combines the heavy ampacity of layered foils with the multidirectional flexibility of braided connectors to eliminate severe structural stresses. |
Plated & Surface-Treated Laminated RailsBest for: Coastal energy installations, marine applications, and highly corrosive industrial environments. Feature: Tin, nickel, or silver plating across the foil layers prevents oxidation and localized thermal spikes. |
Technical Data & Engineering Specifications
Material & Dimensional Capabilities
Base Material: Premium C11000 / Cu-ETP Copper Foil with 99.95% purity for maximum electrical conductivity.
Single Foil Thickness: 0.03mm | 0.05mm | 0.10mm (Standard) | 0.20mm | 0.30mm | 0.40mm | 0.50mm | 0.80mm | 1.0mm. Custom multi-foil layering is available.
Cross-Sectional Area Range: From precision 1.5 mm² links to heavy-duty 5,000 mm² power shunts.
Plating Finish Options: Bare Copper, Tin Plating, Nickel Plating, or Silver Plating.
Advanced Surface Insulation Options
Flame-Retardant Heat-Shrink Tubing: Premium polyolefin sleeving with high dielectric strength; UL94-V0-rated options are available.
PVC Insulation Dipping: Seamless plastisol coating that conforms to complex, multi-bent profiles without edge gaps.
Extruded Insulation Sleeves / PA12: High-end abrasion- and voltage-resistant jackets for EV battery packs and high-density ESS.
Termination & Welded Add-ons
Integrated Molecular Diffusion-Welded Ends: Multi-layer foils are solid-fused without filler metals, producing a single low-resistance copper block.
Battery-Grade Welded Nickel Strips / Tabs: High-purity nickel strips can be precision-welded to foil ends for lithium battery PACK assembly and automated spot or laser welding.
Reinforcement Plates & Stamped Lugs: Thick copper or brass plates can be brazed or welded to flexible foil ends for high-torque, vibration-resistant mounting.
Flex-Agile Production Flow & Engineering Capabilities
01. Foil Cutting & ShapingHigh-speed die cutting and automated shearing ensure clean edge tolerances, while precision punching and laminate riveting align multi-foil geometries before bonding. |
02. Advanced Welding SystemsDiffusion, laser, ultrasonic, and resistance welding options create zero-filler junctions and high-strength terminal reinforcement. |
03. High-Precision End ProcessingCNC-guided cutting, edge polishing, drilling, and machining create burr-free surfaces, precise mounting holes, and custom profiles. |
04. Surface Finish & PassivationAcid cleaning, polishing, passivation, and electro-tin, nickel, or silver plating ensure stable performance in harsh environments. |
05. Bending & FormingPrecision jigs and automated benders form L-bends, Z-bends, and twisted 3D profiles without delaminating internal foil layers. |
06. Premium Insulating SleevingHeat-shrink tubing, silicone-coated fiberglass sleeves, and PVC dip coating provide reliable dielectric clearance and abrasion resistance. |
Key Performance Advantages & Customer Benefits
01. Extremely Low Stray Inductance
Technical Edge: Reduces loop inductance by more than 70% while suppressing damaging IGBT voltage spikes.
Your Benefit: Protects sensitive power modules and significantly extends system operating life.
02. Excellent Electromagnetic Compatibility
Technical Edge: Precision interlayer capacitance acts as a built-in natural electrical filter.
Your Benefit: Reduces EMI and helps equipment meet demanding EMC certification requirements.
03. Space Saving & Simplified Assembly
Technical Edge: One consolidated laminated link can replace dozens of bulky cables.
Your Benefit: Creates a cleaner cabinet layout and can reduce total factory assembly time by more than 50%.
04. Reliable Heat Dissipation & High Ampacity
Technical Edge: Tight copper-to-insulation bonding creates a short thermal path.
Your Benefit: Supports higher current capacity while maintaining lower temperature rise under heavy loads.
05. Modular Customization
Technical Edge: Terminal configurations, mounting-hole matrices, and complex 3D bending angles are fully customizable.
Your Benefit: Enables plug-and-play integration and reduces wiring errors during field deployment.
