1. Industry status

The current copper bar market, mainly includes the following products:

? hard copper bars, usually used in compact battery pack spaces, serve as conductors with insulation such as heat-shrinkable tubing/in-mold injection molding.

? Flexible Copper Strip, with multiple layers of thin copper foil stacked to provide a wide range of bending, twisting and folding shapes to accommodate the required space and interchangeable insulation to meet various temperature or insulation requirements. It is widely used in the current application scenario.

? FlatWire copper bars for connecting individual battery units and electrical components in the Hev, EV, and ESS industries for hybrid electric vehicle, electric vehicles, and Ess rechargeable batteries, it can also be used as an alternative to the conventional bus (die) connection between the main power supply and the distribution equipment.

2.Application of the status quo

As a more suitable for the current industry development needs of the battery Pack Internal Connection Solution, soft copper bar has been more and more applications. The Flexible Copper Busbar is a flexible electrically charged Busbar, which can be bent according to the desired image during the design of the internal structure of the battery pack to optimize the layout, the insulation material can also be changed according to the use environment (temperature, insulation requirements voltage, etc.) . The top of the product is in accordance with the image of the assembly surface. No additional connecting parts are needed.

Tooling cost is low during product development and can be used in narrow spaces such as battery packs (to provide optimum layout) , because it is flexible and easy to assemble, and the tolerance is larger than normal BUSBAR.

Below is an example of a small space arrangement using a soft copper bar:

3.Design of soft copper bar

- Flexible Busbar meets Customer Style Scheme

 1. According to the customer current pattern, select the conductor area (according to the spatial layout of the selection of conductor width and height)

2. Consider the surroundings of the interval through which the Flexiblebusbar passes and the fixed position of the F/B, and design the path.

 3. According to the LS cable FLEXIBLEBUSBARSPEC, 

define dependability test-for FlexibleBusbar composition 

1. FLEIBLEBUSBAR: A product made by bending a thin copper plate to meet the needs of the conductor area and the heel of an insulating sheath. 

2. CONDUCTOR: The busbar shape is formed by the addition of thin copper plates to form an electrically energized busbar [ material: Copper ]

3. Insulation Sheathing: a sheathing that guarantees the insulation of a product. MICATAPE: to ensure fire resistance, use insulating tape which contains soft mica (Optional) . - Flexible Busbar 1) conductor (sheet) : Material: COPPER PLATING: SN 0.5 ~ 1.0 μm thickness: 0.25 mm ± 0.022) insulation Sheath: TPE3) MicaTape: 0.15 mm thickness, Tape.-reliability test with Mica Component

A mature soft copper bar products are subject to the above design and test confirmation.

 Source: Wiring Harness China, by the China Society

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