Aluminum Foil Laminated Connectors

Extreme flexibility: Multi-layer ultra-thin aluminum foil laminated structure minimizes bending stress, adapting to frequent vibration and thermal expansion/contraction inside battery packs.

Molecular diffusion welding: No additional solder; low contact resistance, excellent fatigue resistance, and uniform strong bonding.

Lightweight:  60%~70% weight reduction compared to copper connectors, helping to extend EV driving range.

Reliable conductivity: Pure aluminum provides stable conductivity, reducing the risk of loose contact or local overheating over long-term use.

Flexible customization: Number of layers, length, width, and terminal shape can be manufactured according to customer drawings or samples for various battery modules.

Operating temperature range: -40℃ to +105℃ (short-term up to +120℃)

Suitable environment: Dry or indoor conditions with relative humidity ≤85% (typical inside battery packs)

Installation method: Fixed by bolts or laser welded to battery tabs; avoid excessive bending or twisting of the laminated body

Dynamic applications:  Suitable for low-frequency vibration and small displacement (amplitude ≤2mm, frequency ≤50Hz) during vehicle operation

Electrical requirements:  Suitable for DC or AC systems; rated voltage ≤1500V (for new-energy battery systems)

Check bolt torque every 6 months or during vehicle maintenance (torque wrench recommended).

Clean dust using dry, oil-free compressed air or a soft brush; do not use solvents or corrosive cleaners.

Inspect for delamination, broken foils or discoloration on edges. If single-layer lifting or severe oxidation is found, replace immediately.

Avoid continuous tensile or bending stress on the connector during installation to prevent fatigue life reduction.

Under normal operating conditions (temperature, vibration, and current within design limits), the design service life of aluminum foil laminated connectors matches that of new-energy vehicle battery packs: typically 8–10 years.

Free technical support: engineering consultation, drawings...

Custom orders: lead time & quality report provided before shipment

Zhejiang Bridgold Copper Tech Co., Ltd. is a professional leader China aluminum laminated shunts, aluminum laminated flexible connectors, laminated aluminum connectors, aluminum foil laminated connectors, laminated aluminum foil connectors manufacturers and suppliers with high quality and low price. Welcome to contact us.