The Difference Between Solid Busbar And Flexible Busbar
Apr 01, 2025
1. Concept
Solid busbar: A rigid conductor made of a single metal strip (such as copper or aluminum), usually in the form of a flat strip or tube, with a fixed shape and high mechanical strength.
Flexible busbar: consisting of several thin layers of copper or aluminum, designed to effectively distribute power in AC or DC systems. Weld the copper foil stack in the assembly area to make the ends rigidly connected while maintaining flexibility in the middle.
2. Main differences
| Comparison Item | Solid busbar | Flexible Busbar |
| Structure | Single metal bar or tube, rigid | Multi-layer thin metal sheets stacked, flexible |
| Installation Flexibility | Fixed installation, not easily adjustable | Bendable, adaptable to complex spaces |
| Heat Dissipation Performance | Small surface area, average heat dissipation | Large surface area, better heat dissipation |
| Current Carrying Capacity | High, but limited by cross-sectional area | Can carry larger currents at the same cross-section |
| Vibration Resistance | Poor, susceptible to mechanical stress | Good, adaptable to vibrating environments |
| Application Scenarios | Fixed power distribution (e.g., battery banks, switch cabinets) | Connections needed for moving or compact spaces (e.g., electric vehicles, transformers) |
3. Typical applications
Solid busbar: Solid copper busbar is widely used in fields such as automobiles, battery packs, power storage, and switchgear.
Flexible busbar: suitable for high-voltage connections outside electric vehicle battery packs, transformer jumpers, flexible wiring inside switchgear, etc.
