Flexible Busbars

Creating flexible Busbars is a process that we have perfected over our years of experience within the Metals and Manufacturing industry. Precision measurement, design and equipment that utilises EHRT technology allows us to manufacture the highest quality flexible Busbars for clients in a wide range of industries.

Flexible busbars are created by combining many thin layers of copper or aluminium. A standard unit would consist of copper foils tightly diffusion welded at the mounting areas, which allows each end to remain rigid for other connections whilst keeping the middle of the busbar flexible. They are designed to distribute power efficiently across a AC or DC systems.

As Busbars are the spine of most power applications, providing the all-important interface that the power module needs to connect to the world outside, they must be adequately firm enough to support their own weight. Any external forces such as mechanical vibration and potential environmental factors, which will be considered at the design stage of any system, can have long term effects on the efficiency level of this power infrastructure. Dependent on the country in which this product is used, earthquakes, for instance, could be an extreme consideration when fitting an electrical system.

Factors alongside these external forces to consider when producing busbar systems is any problems arising from precipitation in external configurations and outdoor applications. Thermal expansion from drastic temperature changes stimulated by ohmic heating or variations in the ambient temperature, as well as magnetic forces induced by large currents should all be part of the thought process behind manufacture and installation.

With these environmental factors under consideration, flexible busbars cope admirably with all of these potential problems and provide an elegant solution to a considerable number of inefficiency errors that could arise.

Flexible busbars are used in several different industries because of their durability, robust design for electrical and power applications, and as sensible alternative to large and small cables and rigid busbar sets. Some examples of their uses would be in Electric, Hybrid and Fuel Cell vehicles, as a power link for generators and within switching cabinets as electrical connectors. They can be used as connections between a main busbar and distribution equipment, between a transformer and a bus-duct, and between a bus-duct and an electrical cabinet, which shows the versatility of application that these products can provide.

We can design and manufacture complete products ready to fit which saves installation time and cuts costs, as well as adhere to any specific performance criteria you may have.

Benefits Overview:

Durable with heavy duty assembly and terminations combined with low resistance

High value vibration and shock absorption
Improves electrical conductivity and power efficiency
Preserves flexibility but not at expense of mounting strength or vibration absorption
Infinitely customizable for complete compatibility with specified assembly environment
Available with different forms of insulation as required

Sample Flexible Busbars can be produced on request.