High-Precision Laminated Copper Busbars & Shunts
Explore Our Laminated Copper Busbars
Molecular Diffusion Welded Busbars
Best 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 & ESS
Best for: Electric vehicle (EV) battery packs, Energy Storage Systems (ESS), 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 Shunts
Best for: Extreme vibration environments requiring both 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 Rails
Best for: Coastal energy installations, marine applications, and highly corrosive industrial environments.
Feature: Fully customizable with comprehensive Tin, Nickel, or Silver plating across the entire foil layers to completely prevent oxidation and localized thermal spikes.
Technical Data & Engineering Specifications
Material & Dimensional Capabilities
Base Material: Premium C11000 / Cu-ETP Copper Foil ( 99.95% Purity) for maximum electrical conductivity.
Single Foil Thickness (Ultra-Thin Options):0.03mm | 0.05mm | 0.10mm (Standard) | 0.20mm | 0.30mm | 0.40mm | 0.50mm | 0.80mm | 1.0mm ... Custom multi-foil layering available.
Cross-Sectional Area (CSA) Range:From precision 1.5 mm² links scaling up to heavy-duty 5,000 mm² massive power shunts.
Plating Finish Options:Bare Copper, Tin Plating (Anti-oxidation), Nickel Plating (Thermal stability), or Silver Plating (Ultra-low contact resistance).
Advanced Surface Insulation Options
Flame-Retardant Heat-Shrink Tubing: Premium polyolefin sleeving with high dielectric strength, fully complying with standard fire safety protocols (UL94-V0 rated available).
PVC Insulation Dipping (Plastisol Coated): Continuous fluid liquid dipping that conforms perfectly to complex, 3D multi-bent profiles with zero seams or edge gaps.
Extruded Insulation Sleeves / PA12: High-end extruded jackets designed for modern EV battery packs and high-density Energy Storage Systems (ESS), offering maximum abrasion and voltage protection.
Termination & Welded Add-ons
Integrated Molecular Diffusion-Welded Ends: Multi-layer foils are solid-fused together without adding any filler metals, ensuring the ends behave like a single, solid low-resistance copper block.
Battery-Grade Welded Nickel Strips / Tabs : We can precision-weld thin, high-purity nickel strips onto the copper foil ends. This is specifically optimized for lithium battery PACK assembly, enabling flawless, high-strength automated spot/laser welding directly to battery cells.
Reinforcement Plates & Stamped Lugs : We can braze or weld thick solid copper/brass plates onto the flexible foil ends to handle heavy-duty torque fastening during high-vibration bolt mounting.
Flex-Agile Production Flow & Engineering Capabilities
- Foil Cutting & Shaping
Die Cutting & Auto Cutting: High-speed automated shearing ensures clean, microscopic edge tolerances for multi-layer foils.
Punching & Laminate Riveting: Precision stamping and automated pre-stack riveting ensure perfectly aligned multi-foil geometries before bonding.
- Advanced Welding Systems
Diffusion Welding: Solid-state molecular fusion under extreme heat and pressure, delivering zero-filler, zero-resistance junctions.
Laser & Ultrasonic Welding: High-precision laser fusing and ultrasonic bonding optimized for ultra-thin micro-foils and delicate electronic tabs.
Resistance Welding: Standard industrial resistance welding tailored for rapid, high-strength terminal reinforcement.
- High-Precision End Processing
Cutting, Edge Polishing & Drilling: CNC-guided milling and post-weld trimming deliver entirely burr-free surfaces and perfectly center-aligned mounting holes.
CNC Machining: Specialized custom profiles and strict geometrical tolerance calibrations driven by direct multi-axis CNC routing.
- Surface Finish & Passivation
Polishing & Acid Cleaning: Thorough multi-stage chemical acid cleaning and mechanical polishing to eliminate surface oxides.
Passivating & Shielding: Advanced surface passivation to ensure long-term stability in harsh micro-climates.
Electrical Plating: Comprehensive Electro-tin, Nickel, or Silver plating options to shield the copper from localized thermal degradation.
- Bending & Forming
Multi-Angle 3D Bending: Utilizing precision forming jigs and automated benders to shape laminated busbars into complex L-bends, Z-bends, or twisted spatial profiles without delaminating the internal foils.
- Premium Insulating Sleeving
HS Tube (Heat-Shrink Tubing): Flame-retardant (UL94-V0 rated options) polyolefin sleeves for quick, reliable dielectric clearance.
Glass Fiber Tube: Heavy-duty silicone-coated fiberglass sleeving built to withstand extreme temperatures and harsh abrasion.
PVC Dip Coating (Plastisol Dipping): Seamless, continuous fluid liquid insulation that perfectly wraps around severe multi-bent 3D angles with zero air pockets.
Key Performance Advantages & Customer Benefits
- Extremely Low Stray Inductance
Technical Edge: Reduces loop inductance by >70% while effectively suppressing damaging IGBT voltage spikes.
Your Benefit: Provides ironclad protection for sensitive power modules and significantly extends the system’s operational lifetime.
- Excellent Electromagnetic Compatibility
Technical Edge: Precision interlayer capacitance architectures act as a built-in, natural electrical filter.
Your Benefit: Drastically reduces EMI (Electromagnetic Interference), helping your equipment pass strict EMC certifications smoothly and easily.
03.Space Saving & Simplified Assembly
Technical Edge: A single consolidated laminated link replaces dozens of bulky, unmanageable cables.
Your Benefit: Delivers a significantly cleaner cabinet layout and cuts total factory assembly time by >50%.
- 04. Reliable Heat Dissipation & High Ampacity
Technical Edge: Ultra-tight copper-to-insulation micro-bonding ensures a remarkably short thermal path.
Your Benefit: Unlocks higher current-carrying capacity while maintaining a much lower temperature rise under heavy loads.
- Modular Customization
Technical Edge: 100% tailor-made terminal configurations, precise mounting hole matrices, and complex 3D bending angles.
Your Benefit: True plug-and-play integration that entirely eliminates human wiring errors during field deployment.
