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Flexible Expansion Connectors/
Supple Bars

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Flexible Expansion Connectors

Range of application:
Our laminated flexible connectors are necessary everywhere where it is impossible to use solid bus bars to transfer the current. Main applications are:

• Expansion-equilibration in bus bar-systems
• Expansion-equilibration to connect transformers and generators
• Vibration-equilibration
• Moveable current-transfer in machines and devices
• Switching elements in switches

Description:
Laminated flexible connectors are made out of copper- or aluminum-foil in bare, in case of copper alternatively in tinned configuration. The foil-cutoffs will be stacked and after this united at the contact-areas by using a tuned process for the later application. For this we use foils from 0,05 up to 1 mm thickness. The width and thickness of the connector is chosen by our customers.

In case of aluminum-connectors a solid piece of aluminum will be welded at the end of the foils.

Cross-section/max. load:
In standard design we offer connectors up to a cross-section of ca. 5000 mm² . The maximum current-load is conditioned by a wide number of factors. Please contact us for detailed information.

We also develop special-designs for your individual applications.

Procedure:
We use the following procedures to produce laminated flexible copper connectors:

• Press welding
• Electron-beam welding
• Melt welding
• Gas-shielded welding
• Solder
• Press rivet

Procedures to produce aluminum laminated connectors:

• Melt welding
• Electron-beam welding

Materials:
In order to optimize the max. load and conductance of our connectors we use exclusively pure and extreme transmittable materials as foils and sheet metal covers.

• For copper-connectors Cu-ETP (previously E-Cu) and Cu-HCP (previously SE-Cu) according DIN EN 13599
• For Aluminum-connectors E-Al 99,5 according DIN EN

We advise, that in case of using different materials than above the conductance of the connectors become bad.

Strength:
For different cases of application we use various foils from F20 - F30. The used strength class depends on the mechanical stress of the connector in operation.

Form:
For different applications we offer a wide range of standard shapes and also special designs :

• Bows in S-, U- and V-Form
• Straight connectors
• Bended connectors according your wishes
• U-forms for roll-movements

Supple Bars

Construction and technical data
Supple bars are isolated, flat flexible electrical conductors. They consist of several layers of bare or tin coated CU-ETP strips (formerly E-Cu) and are insulated with a highly flexible high quality PVC composite. The result is the technical data for our standard designs as follows:

Insulating material

• Special PVC composite
• Shore hardness approx. 85 A
• Max. tensile strength 19.6 MPa
• Max. breaking extension 365%
• Highly flame retardant, self-extinguishing
• Insulation thickness approx. 2 mm

Supple bar

• Working temperature - 40° C to + 105° C
• Max. operating voltage 1 kV
• Breakdown rating 20 kV/mm

Applications and instructions for use
The high flexibility of insulated supple bars and space-saving flexible components makes them suitable for use in the installation of all types of electrical equipment. They have become particularly well established as connectors in switchgear and between transformers, generators, switching devices and in prefabricated power networks. As a consequence of their large surface area and hence their favourable thermal radiation properties, they can handle heavier current loads than e.g. busbars of the same cross-section. Their high flexibility of their insulation is a particularly outstanding feature of our supple bars. Even those with a larger cross-section can be shaped without difficulty. The connection level can also be changed by bending and twisting through 180°.

Simple mounting by drilling, punching or underside clamping. Please note that it is necessary to tightly mount the bars before punching or drilling to avoid displacement of the strips. Only drill/punch or cut supple bars to size once the twisting process is completed, as the strips all slide to a different extend.

Also available in a halogen-free variant. Plaese refer to New Products.

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