We present a new solution for applications in the field of flex busbars

Flex busbars are flexible HV connectors that are used for power distribution in the field of e-mobility. This can involve applications in the battery sector (storage) or in the busbar system. The purpose of these connectors is to compensate for possible tolerances with regard to the routing strategy in the HV electrical system of the vehicle.

Depending on the desired flexibility, flex busbars can consist of a stack of individual films with a thickness of e. g. 0.05 mm to 1 mm in any number or of braids in the desired cross-section. In both versions, the ends are welded over large areas. In these cases, processing areas of up to 1000 mm² are required for optimum current transmission. Our new three-phase machines fully weld the foils or compact the strands in a single operation.

These systems are characterized by optimal current distribution over these large areas. Due to the use of resistance welding, no direct cooling of the components by flooding them with water is necessary, unlike conventional processes. This eliminates the otherwise unavoidable oxidation of the HV connectors and the time-consuming drying of the finished components.

The special design of our technology results in reliable joints, while at the same time the process speed is many times higher than in conventional methods. As a direct consequence of this, there is also no tarnishing of the surfaces. Thus, the function and the service life of the HV connectors are not impaired by welding.

On request, we offer manual systems as well as turnkey systems for the production of these connectors, designed to your specifications. Optional downstream punching and smoothing processes also make it possible to maintain the desired surface quality for subsequent production steps.

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