How are insulated plastic-coated flexible copper connectors primarily connected? When you use metal flexible connectors, have you considered their main method of connection? Normally, as we know, connections are made by welding. For insulated plastic-coated flexible copper connectors, there are two common welding techniques: pressure welding and brazing.

If an insulated plastic-immersed copper flexible connector is connected using pressure welding, the copper foil stacked parts need to be pressed together first, then molecular diffusion welding is used, and the pressure welding is formed by heating with a large current. Generally speaking, the thickness of the copper foil here is 0.05mm-0.3mm.

If an insulated plastic-dipped copper flexible connector needs to be connected by brazing, the copper foil stack should also be pressed together first, and then instead of using diffusion welding, a silver-based brazing filler is used to braze it with the flat copper block to form a complete copper flexible connector.

Generally, insulated plastic-dipped copper flexible connectors need to use appropriate welding methods based on actual requirements and selection. For example, to ensure the flatness of the contact surface, when A is greater than 90mm and B is greater than 60mm, it is suitable to use the process of pressing and welding copper plates onto the contact surface; whereas when A is greater than 140mm and B is greater than 130mm, the insulated plastic-dipped copper flexible connector should use the brazing process.

The answer to why the solder joints of insulated PVC-coated copper flexible connectors are firm is mainly that they are primarily connected using advanced welding technology, making the welding not easily deformed by external forces. Therefore, such copper flexible connectors are widely used, suitable for the performance requirements of busbars under high current, and can also be used as other conductive flexible connector components.