Premium Expansion Busbars
Have you ever wondered how much physical stress is present in a modern switchgear, a transformer, or the battery pack of an electric vehicle? In addition to massive currents, enormous forces are at work here. Copper expands when heated and contracts when cooled. Generators or harsh environmental conditions can lead to constant vibrations, which in turn can cause problems. Anyone who uses only rigid connections here risks mechanical fractures and costly system failures. Our solution is flexible Busbars, also known as Expansion Busbars. They provide a flexible connection in modern power transmission.
When form follows function
Press-welded connections
The key advantage of our Expansion Busbars lies in the manufacturing of the end pieces. To achieve this, we use the so-called press-welding process, also known as molecular diffusion welding. Unlike conventional methods, we do not weld the layered lamellae at the ends using additional solder or press them into a sleeve. Instead, the copper lamellae are fused directly together under extreme pressure and precisely controlled heat. The key physical feature is that the individual lamellae merge into a single, homogeneous, solid copper block in the contact area. Since no foreign metal such as solder is used, the electrical resistance of the connection corresponds to that of pure electrical copper. A uniform transition also ensures that no localized heat build-up occurs. This results in the overall system becoming more efficient. Since neither crimp sleeves can loosen nor solder age, the contact surfaces of Expansion Busbars are considered maintenance-free.
Our Top Sellers
A flexible busbar is only as good as its ability to dissipate mechanical stress away from the connection points.
By using ultra-thin copper lamellae in the core, these components can be formed into a wide variety of geometric profiles to compensate for specific movements. We always perform manufacturing of our Expansion Busbars according to custom specifications and based on customer requirements.
Here are the Expansion Busbar shapes that are most frequently requested:
I-Shape
The classic solution for pure axial compensation. It is perfect for accommodating linear thermal expansion in long busbar systems.
L-Shape
Ideal for tight spaces in control cabinets. It elegantly routes cables around corners and absorbs movement in two axes.
S-Shape
The perfect solution when two rigid connections aren’t perfectly aligned due to structural constraints. This profile effortlessly compensates for height and lateral misalignment in three-dimensional space.
U- or V-Shape
For environments with high levels of vibration. Its distinctive loop absorbs massive, three-dimensional vibrations from transformers or motors.
For industrial use or batteries
Flexible Expansion Busbars adapt not only mechanically but also dimensionally. We distinguish between two sizes here:
1. Industrial facilities with high-current applications
In traditional plant engineering, grid infrastructure, wind turbines, and induction furnaces, currents in the four-digit ampere range flow.
This is where robust Expansion Busbars with cross-sections ranging from 50 to over 1,200 mm² are used. They typically consist of copper strips 0.10 to 0.30 mm thick and are extremely resistant to mechanical stress.
2. Mobile applications with limited space
At the other end of the spectrum, for example, in electric mobility (EV battery packs), sensitive semiconductor modules, or compact circuit breakers, every millimeter counts.
Here, the cross-sections shrink to a delicate 1.5 to 40 mm². The individual lamellae are wafer-thin, with a thickness of up to 0.02 mm. The result is an almost weightless, omnidirectional flexibility that protects the sensitive contacts of the battery cells from microvibrations.
Maximum capacity meets a global network.
We are proud to offer the largest press-welding capacity in Europe. Our customers can always count on uncompromising quality, whether it’s a high-precision small-batch production run for prototypes in the automotive sector or high-volume production for global grid expansion.
Thanks to our new global umbrella company Pantheon Electric, together with our partners International Wire, International Wire Europe, Special Corde, Hussey Copper, and our brands EMS Elektro Metall Spezialprodukte Polska, Vision®Electric, buzzbar®, and SPS Standard Produkte Schwanenmühle, we have taken our reach to a whole new level.
Design & Engineering
As specialists in custom high-current technology, we leave nothing to chance and support projects from the initial concept through to final integration. Upon request, our engineering experts are also happy to use state-of-the-art multiphysics simulations to calculate magnetic fields, current density distributions, and thermal power dissipation under real-world load conditions in advance. This precise combination of analysis and decades of design experience ensures that the Expansion Busbar is precisely optimized for the specific vibration frequencies, cross-sectional requirements, and spatial conditions of your system. From custom prototype development to complex assembly engineering, we deliver turnkey system solutions.
Get your project off to a strong start
Whether in sophisticated mechanical engineering or at the heart of an electric vehicle, our flexible Expansion Busbars provide the mechanical flexibility required by today’s high-performance electrical systems. With our press-welding manufacturing capabilities, among the largest in Europe, and the global strength of Pantheon Electric behind us, we are your partner for the next generation of power distribution.
What mechanical challenges do you need to solve in your current project? Contact our engineering experts, we’ll bring flexibility to your system!
