Gallery:
G Corner designs and manufactures copper flexibles for use as expansion joints and transformer-rectifier (T/R) connections within DC busbar systems. Constructed from multiple laminated layers of high conductivity copper, they absorb thermal expansion, contraction, vibration, and installation misalignment, reducing the mechanical stress transmitted into busbars and connected equipment while maintaining an efficient, low loss current path.
Flexible busbars are used where a rigid connection would transmit mechanical stress into adjacent equipment, whether from thermal expansion and contraction, assembly tolerances, or vibration. Within DC busbar systems they are used as expansion joints and as transformer-rectifier (T/R) connections.
Each flexible is built from multiple laminated layers of high conductivity copper: Cu-ETP, oxygen free copper, or Cu-PHC. The lamination gives the flexible its movement capability, while the increased surface area of the individual strips provides a lower temperature rise than an equivalent solid busbar at the same current density.
G Corner manufactures four categories of flexible busbar for different connection points within the DC electrical system. Each is engineered to the specific dimensions, current rating, and flexibility requirements of the installation.
Flexible Busbars
Installed within the busbar system to absorb the linear expansion and contraction caused by thermal cycling at full load conditions, preventing that movement from stressing adjacent busbars and equipment. Typically around 1.2 metres in length, sized to match the busbar dimensions and carrying the same current density as the solid busbar, and supplied flat or preformed for faster fitment.
Connect the positive and negative DC busbar feeders to the transformer-rectifier unit, preventing busbar expansion, installation misalignment, and operational vibration from stressing the T/R terminals. Manufactured from multiple laminations of high conductivity copper foil from 0.05mm, giving greater flexibility than an expansion flexible and dissipating the heat generated at higher current densities.
Connect fixed busbar sections to DC isolation switches, absorbing the differential movement at the switch terminals that would otherwise loosen bolted connections and damage the joint. Engineered to the terminal geometry and current rating of both the switch and the busbar, with tin, silver, or nickel plating available.
Intercell and end-cell flexibles connecting the busbar system to electrolyser equipment at cell level, carrying high continuous DC current while accommodating the relative movement caused by thermal expansion, operational loading, and installation tolerances. High performance sleeving insulation is available where the connection requires it.
Applications
Laminated flexibles are primarily used in electrochemical processing industries where high-current DC power is distributed through busbar systems to electrolytic cells. Key applications include copper, zinc, nickel, cobalt, and manganese electrowinning, copper and precious metal electro-refining, chlor-alkali production, and the rapidly growing green hydrogen industry, where large-scale water electrolysers require reliable high-current power connections.
These flexibles are installed between fixed busbar systems and electrolyser cells to accommodate thermal expansion, vibration, equipment movement, and maintenance activities while maintaining a low-resistance electrical connection.
The principal market for electrolyser connection flexibles comprises mining and metals producers, chemical processing plants, hydrogen production facilities, and engineering, procurement, and construction (EPC) contractors involved in new-build and plant expansion projects.
Demand is also driven by refurbishment and life-extension programmes at existing electrolytic plants, where replacement flexibles are required to improve reliability, reduce maintenance, and support higher production capacities.
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