Flexibles are electrical conductors that connect two components absorbing movement and vibrations. They are made of

• copper laminates
• copper braids
• aluminum laminates

Presswelded Copper Laminated Flexibles

Copper laminated flexibles are welded together at each end utilizing presswelding technology. Presswelding provides superior technical characteristics that result in the following advantages:

• smaller cross sections for same amperage
• cooler terminals by reduced power losses

In this phase a terminal is created which can be drilled, bent or machined in the same way as a solid bar. Presswelding technology is "state-of-the-art". EMS has used this technology since the 1970's.

The presswelding process is well established in Europe as the optimal technology for welding packaged copper laminates. Presswelding can be used for a limited number of materials like copper, copper alloys, nickel, chrome, etc. Other processes such as MIG- or TIG-welding allow also to produce flexible connections but at a higher resistance when compared to presswelding. Presswelding has lowest connection resistance because no additional weldmetals or auxiliary matter is used in the weld.

Compressed Braid Copper Flexibles

Copper braided flexibles are used in applications that move in 3 directions. The copper braids consist of wires with a thickness between 0.07 mm and 0.1 mm. The copper braid is held together by a copper tube which is then mechanically compressed from all four sides using a special double press system. Most manufacturers generally compress from the top thereby allowing the sides to bend out. The result of EMS' technology is a highly compressed terminal palm with lower short and long-term resistance than comparable products.

MIG-welded aluminum laminated flexibles

Presswelding, the ultimate technology for combining copper laminates, cannot be used to economically produce aluminum flexibles. Aluminum laminates and solid bars are MIG-welded. This welding method is based on an electrical arc melting both parts tof he solid terminal palm and the laminate package. Welding metal is then pushed into the arc, liguified at high temperature forming a weld seam. To protect the liquid metal from oxidation an inert gas like Argon flows out over the welding zone. This provided the name of the welding method: Metal Inert Gas - welding.