Braided Tin Coated Copper Flexible Connectors
Products Description
Braided Tin Coated Copper Flexible Connectors use multi-strand high-purity copper wires as the base material. A high-density conductor structure is formed through a precision braiding process, and the copper wires are uniformly tin-plated. This significantly improves the product's oxidation resistance, corrosion resistance, and solderability while maintaining low-resistance transmission capabilities.
Its core structural features include:
Multi-strand fine-diameter copper wire braiding for more uniform current distribution
The braided structure can be freely bent, relieving mechanical stress
Complete tin plating coverage, suitable for various connection methods
Ends can be crimped, punched, or soldered as required
This structural design ensures stable electrical and mechanical performance even under complex operating conditions.
Lean Structural Design: Flexible Adaptation Optimization Centered on Conductivity Efficiency
| Precision Braided Structure: Balancing Flexibility and Conductivity | Utilizing a multi-strand fine copper wire precision braiding process, the braiding density has been optimized through mechanical and electrical simulations. While ensuring ultimate flexibility, it maximizes the conductor's cross-sectional area, enhancing current-carrying capacity. The advantages of braided structures are: First, strong flexibility and compensation capabilities, enabling multi-angle and multi-directional bending adaptation, effectively compensating for dimensional deviations during installation and vibration displacement during equipment operation, avoiding stress concentration in rigid connections; second, excellent heat dissipation performance, with the braided gaps forming natural heat dissipation channels, combined with the high thermal conductivity of copper, quickly dissipating heat generated during current transmission and preventing localized overheating; third, outstanding fatigue resistance, as the braided structure evenly distributes stress across each copper wire, allowing it to withstand more frequent bending and vibration compared to a single thick conductor, extending its service life. |
| Integrated End Connection Design: Ensuring Connection Robustness and Low Contact Resistance | The ends employ integrated crimping or high-frequency welding processes to firmly connect the braided conductor to the copper terminals, unlike traditional riveting processes, avoiding problems such as loose connections and excessive contact resistance. The crimping process uses customized molds to precisely control the crimping force and depth, ensuring a tight fit between the braided conductor and the terminal, and stable contact resistance; the welding process uses high-frequency induction welding, resulting in uniform welding temperature, strong welds, and no incomplete or false welds, ensuring stable current transmission. Meanwhile, the terminal design conforms to international standards, allowing direct connection with various electrical components and improving assembly convenience. |
| Customized Size and Structure Design: Adaptable to Diverse Electrical Scenarios | Customized product size and structure design is supported based on customer electrical parameters and installation requirements: Firstly, conductor cross-sectional area customization allows adjustment of the number and diameter of braided copper wires according to current load requirements, achieving precise matching of different current-carrying capacities; secondly, length and width customization adapts to different installation space limitations, especially suitable for electrical connections in confined spaces; thirdly, end structure customization allows for customization of terminal shape, aperture, and connection method according to the type of mating component, achieving precise adaptation to a specific scenario; fourthly, special protection design allows for the addition of insulating sleeves, sealing gaskets, and other protective structures at the ends to enhance protection levels in harsh and corrosive environments. |
| Optimized Insulation Protection: Improved Safety | For scenarios requiring insulation protection, customized insulation sleeve solutions are provided, using high-temperature resistant and aging-resistant insulating materials (such as silicone rubber and polyvinyl chloride) to wrap the braided conductor tightly, preventing short circuits between the conductor and surrounding components and improving safety. The insulating sleeve features clear markings, including product specifications and rated current, printed on its surface, making it easy to identify and install. It also has good wear resistance and can withstand friction damage in complex installation environments. |
Material Advantages: Synergistic Effect of T2 Copper and Tin Plating
T2 Grade High-Purity Oxygen-Free Copper
We select T2 grade copper with a purity of over 99.9% as the base material. This copper material has extremely low resistivity and extremely high thermal conductivity. Its high purity means very few impurities, thus avoiding localized overheating caused by impurities. High thermal conductivity also allows for rapid heat dissipation from joints, preventing heat buildup that can lead to insulation aging or solder melting.
Soft Annealing Treatment
Copper wire undergoes work hardening during drawing, becoming hard and brittle. To achieve ultimate flexibility, we perform a precise annealing treatment on the copper wire. This process eliminates internal stress, restores the ductility of the copper material, allowing the copper wires to slide freely rather than rigidly resist when the braid is stretched, greatly improving fatigue life.
Electrochemical protection of tin plating
Tin has better chemical stability than copper and forms a good metallurgical bond with copper. Tin plating not only isolates the contact surface from air and corrosive media but also improves the coefficient of friction of the contact surfaces. In applications requiring frequent insertion, removal, or sliding of contacts, tin plating acts as a self-lubricant, reducing mechanical wear.
Wide Range of Critical Applications
New Energy Vehicles and Electric Drive Systems
Serving as the connection between modules within the battery pack, the phase connection between the motor and controller, and the safety grounding wire between the vehicle body and chassis, Tinned Copper Braid Earthing Tape must withstand continuous vibration and high current surges.
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Power Electronics and Frequency Conversion Equipment
Used to connect IGBT modules, capacitor busbars, transformer terminals, etc., absorbing stress caused by thermal expansion and contraction, and bearing the transmission of high-frequency, high-current signals while suppressing parasitic inductance.
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Industrial Robots and Automation Equipment
Providing power, signal, and grounding connections between moving parts such as robot joints, sliding platforms, and robotic arms, Round Stranded Flexible Cords must keep pace with high-speed, high-precision repetitive motion.
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Rail Transportation and Aerospace
Used for grounding pantographs, doors, bogies, and connections between airborne equipment, with extremely stringent requirements for reliability, lightweight design, and fatigue resistance.
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High-end medical and scientific research equipment
Flexible copper bar provides stable, noise-free electrical connections inside precision instruments that require precise movement or vibration isolation.
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