At present, the copper platoon market mainly includes the following products: Hard copper bar, usually used in compact battery pack space, acts as a conductor, and its insulation is heat-shrinkable tube/in-mold injection molding, etc. Soft copper bar, laminated with many layers of thin copper foil, has high flexibility, can provide various bending, twisting and folding shapes to adapt to the required space, and can replace insulation to meet various temperature or insulation requirements. It is widely used in current application scenarios. FlatWire copper bar is used to connect single battery units and electrical components in HEV, EV and ESS industries. It is suitable for rechargeable batteries of hybrid electric vehicles, electric vehicles and ESS, and can also be used as an alternative to the traditional bus (mold) connection between main power supply and distribution equipment.
Application of soft copper bar As a battery pack internal connection solution(Wire Harness) that is more suitable for the current industry development and Kable-X needs, soft copper bus has been used more and more. Soft copper BUSBAR is a kind of flexible bus bar (thin copper plate that can be energized cumulatively). In the process of internal structure design of battery pack, it can be bent according to the required image to achieve the optimal layout. At the same time, the insulation material of the Cable Assembly can also be changed according to the conditions of use environment (temperature, insulation required voltage, etc.). The top of the product matches the image of the assembly surface, and no additional connecting parts are needed. In the process of product development, the required Tooling Cost is low, and it can be applied to narrow spaces such as battery packs (providing the optimum layout), because it has certain flexibility and is easy to assemble. Compared with the general BUSBAR, the allowable tolerance can be larger. Design of soft copper bar 1. Flexible Busbar meets customer's style scheme (1) according to the customer's current pattern, select the conductor area (select the width and height of the conductor according to the spatial layout) (2) Considering the surrounding environment of the section where the Flexiblebusbar passes and the fixed position of F/B, design the path. (3) according to the LS cable Flexible Busbar Spec, carry out the reliability test 2. Definition of Flexible Busbar (1)Fleible Busbar: a product made by accumulating thin copper plates to meet the conductor area, sheathing an insulating sheath, and bending with the required layout. (2) Conductor: by accumulating thin copper plates, a busbar shape that can be electrified is formed [material: copper] (3) Insulation sheath: sheath [TPE] to ensure the insulation performance of products. (4)Mica Tape: the insulating tape used to ensure fire resistance contains soft mica (Optional). 3. Material of Flexible Busbar 1) conductor (sheet): Material: copper Coating: Sn 0.5~1.0㎛ Thickness: 0.25mm 0.02 2) Insulation sheath: TPE 3) Mica Tape: Tape with thickness of 0.15mm and MICA component.
