Introduction
Electric vehicle and battery power distribution systems typically consist of rigid busbars that also require Flex Busbars at specified interconnections.
Flex Busbars allow vibration absorption, thermal expansion, assembly tolerance and space saving.
Flex Busbars are essential to connect the rigid busbars to EV motors, Inverters, E-axles and Battery packs.
Due to their high flexibility Flex Busbars are used for Disconnectors.
Technical Details
Flex Busbar are electrical conductors made of copper foils stacked together to reach the copper section required and manufactured according to the design requirements.
The copper foils are press-welded together in some area, typically at the sides.
Flex Busbar allows thermal expansion and minimize the vibration transmission.
> Flex Busbar can be equipped with inserts and other components (e.g. shrink tube protections).
> Flex Busbar can be protected from corrosion by pre-plated layers (Nickel or Silver).
Flexible Busbars Made in Italy
Materials
Flex Busbars are normally made of copper foils as per EN 13599, thickness 0,10-0,20mm, material Cu-OF.
Quality controls
> Dimensional control by optical instrument and/or gauges
> Voltage drop test to check the correct conductivity of press-welding process
> Metallographic inspection to evaluate the correct joining of copper foils where press-welded
> Contamination acceptability limits
> Flexibility test
> Rugosity of contact area
Certifications
> Letter of Conformance IATF 16949. Activity: Electrical busbar production.
