Insulated Flexible Busbar T2 Copper Busbar Factory Customizable

Material:

T2 copper, copper content ≥99.95%

Surface treatment:

Tin-plated, bare copper

Rated current:

125A-1600A

Cross-sectional area:

24mm²-1200mm²

Length:

Default 2000mm, customizable

Dimensions:

Select the number of busbar layers, width, and thickness of each layer based on the terminal width of the connected device.

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Description

A Flexible Busbar, also known as a flexible laminated busbar or flexible copper/aluminum bar, is a conductive component made from multiple layers of thin copper or aluminum laminates, stacked and bonded together with insulation. Unlike rigid busbars or multiple cable connections, a flexible busbar can bend, twist, or fold to adapt to compact layouts and complex wiring paths. This flexibility reduces installation time, saves space, and improves performance, making it a preferred solution in modern electrical power distribution and energy systems.

Technical Parameter

Structure and Feature

1. Ultra-Flexible Design

It can bend, twist, or fold, making installation easy in compact or complex environments.

2. High Current Capacity

Despite its flexibility, laminated structures allow high current and short-circuit resistance.

3. Space & Weight Savings

Smaller and lighter than equivalent cable bundles or rigid bars, reducing installation space.

4. Faster Installation & Lower Cost

Fewer cable lugs and connections required; reduces labor time and assembly complexity.

5. Insulated & Safe

Fully covered with flame-retardant insulation, preventing electrical hazards.

6. Durable & Vibration-Resistant

Handles vibration, thermal cycling, and expansion better than rigid busbars.

7. Improved Heat Management

Laminated thin layers distribute heat evenly, lowering temperature rise and losses.

8. Customizable

Length, cross-section, number of layers, insulation thickness, and terminal type can be tailored.

Applications

Flexible busbars are widely used in industries where high current and compact design are required:

Electric Vehicles (EVs & Hybrids) – Battery packs, inverters, DC-DC converters.
Renewable Energy Systems – Solar PV, wind power, energy storage battery banks.
Switchboards & Control Panels – Compact connections in distribution panels.
Data Centers & Telecom – Space-efficient, low-loss power distribution.
Railway, Marine & Aerospace – Reliable under vibration and dynamic conditions.
Industrial Automation & Robotics – Motor drives, servo systems, large power equipment.

Flexible vs. Rigid Busbar – Which is Better?

Aspect	Rigid Busbar	Flexible Busbar
Flexibility	Fixed shape, hard to bend	Can bend, twist, and fold easily
Installation	Requires more time & fittings	Faster, fewer parts needed
Space Use	Bulky	Compact, saves space
Vibration Resistance	Prone to loosening	Excellent vibration tolerance
Heat Management	Good but localized	Even heat distribution
Cost	Lower initial	Higher initial cost, but reduces the total cost of ownership

Conclusion: Flexible busbars excel in applications with space limits, vibration, or frequent thermal cycling, while rigid busbars remain suitable for large, fixed installations.

Case Studies

Case 1: EV Battery Pack Integration
A bus manufacturer replaced heavy cable bundles with high current ultra-flexible busbars, reducing system weight by 25%, cutting installation time by 40%, and lowering heat rise across the battery pack.

Case 2: Data Center Power Distribution
By switching from rigid busbars and multiple cables to insulated flexible busbars, a large data center achieved cleaner layouts, reduced hot spots, and cut annual maintenance costs by nearly 20%.

Case 3: Renewable Energy Storage System
In a hybrid solar-storage installation, flexible insulated busbars were used between inverters and storage modules, ensuring reliable performance in outdoor conditions (-40 °C to +105 °C) with excellent electrical insulation.

Conclusion

Flexible Busbars are redefining modern power distribution. With ultra-flexible laminated design, high current capability, reliable insulation, and superior durability, they provide a safe, efficient, and space-saving solution for electric vehicles, renewable energy, industrial panels, and data centers.

As one of the leading flexible busbar manufacturers, GRL offers flexible copper busbars, insulated flexible bus bars, high current ultra-flexible busbars, and customized solutions tailored to your project requirements.

If you’re considering whether flexible or rigid busbar is better for your application, GRL can provide expert advice and engineering support to ensure the most efficient and reliable solution.