Copper foil flexible connectors have become a key component in the field of new energy, mainly due to their unique material properties and technological advantages, which can effectively meet the requirements of high current, flexible connections, and reliability. The following is a specific analysis of the reasons:
1. Excellent conductivity and low energy consumption
-High conductivity: Copper's conductivity is second only to silver and much higher than other common metals such as aluminum. It can efficiently transmit high currents in new energy equipment such as batteries, motors, and electronic control systems, reducing energy loss.
-Low resistance heating: The flat multi-layer structure of copper foil soft connection increases the cross-sectional area, reduces resistance and heating, avoids safety hazards caused by high temperature, and is suitable for high-power scenarios (such as electric vehicle power battery packs).
2. Flexible design adapts to complex working conditions
-Anti vibration and displacement compensation: New energy equipment (such as automotive batteries and wind power systems) are often affected by vibration or thermal expansion and contraction. The flexibility of copper foil soft connections can absorb mechanical stress and prevent loosening or breakage at the connection.
-Space adaptability: The bendable and foldable features facilitate layout in narrow or non-linear spaces (such as bridging between battery modules), enhancing design flexibility.
3. High reliability and long lifespan
-Corrosion and oxidation resistance: Through surface treatments such as tin plating and nickel plating, copper foil soft connections can resist harsh environments such as humidity and salt spray, extending their service life.
-Strong fatigue resistance: Compared to rigid connections (such as bolted connections), it is less likely to fail due to repeated deformation under dynamic conditions, making it suitable for mobile devices (such as electric vehicles).
4. Lightweight and heat dissipation advantages
-Lightweight: The thin layer stacking structure of copper foil is lighter than traditional copper bars, which helps to reduce weight of new energy equipment (such as improving the range of electric vehicles).
-Fast heat dissipation: The large surface area and high thermal conductivity of copper facilitate heat diffusion, avoiding local overheating (such as thermal management during battery pack charging and discharging).
5. Specific demand matching in the field of new energy
-Power battery system: Used for series and parallel connection between battery cells, it needs to carry hundreds of amperes of current and withstand deformation during charge and discharge cycles (such as lithium battery expansion).
-Hydrogen fuel cell: The conductive connection between the bipolar plate and the stack requires low contact resistance and resistance to chemical corrosion.
-Photovoltaic and energy storage: High frequency and high current scenarios such as inverters and transformers require low impedance connections.
6. Process and cost advantages
-Customization: Flexible adjustment of size and shape through welding, crimping and other processes to adapt to different models of equipment.
-Large scale production: The copper foil processing technology is mature, the cost is controllable, and it is suitable for large-scale application in the new energy industry.
Disadvantages compared to traditional solutions
Traditional hard connections (such as copper bars) are prone to loosening in vibration environments, while copper cables, although flexible, have insufficient cross-sectional area. Copper foil soft connector combines the advantages of both and becomes an ideal choice for high current scenarios in new energy.
