Copper Braid Flexible Bus Bar
Products Description
In modern high-power systems, connections between devices not only need to carry large currents but also withstand factors such as thermal expansion and contraction, vibration and shock, and installation structural deviations. Copper braid flexible bus bars were developed to address these engineering challenges:
High conductivity and flexibility: Can be bent in multiple directions, and installation is not limited by equipment location.
Absorbs mechanical stress: Can compensate for structural misalignment caused by thermal expansion and contraction of equipment.
Reduces contact resistance: The multi-strand braided structure ensures uniform current distribution and reduces heat generation.
Higher safety redundancy: Maintains stable connection performance under high current conditions.
These products are commonly used to replace traditional copper busbars and are indispensable key connectors in new energy systems.
Key Product Features: Precisely Matching Stringent Requirements for Flexible Conductive Power Transmission
Copper Braided Current Equalisation Structure
Utilising multiple strands of high-purity copper wire precisely woven together, the conductive path is distributed in a mesh pattern. Current is evenly conducted between the copper wires, effectively reducing the skin effect. Simultaneously, the gaps between the braids form natural heat dissipation channels, preventing localised heat accumulation.
01
High Flexibility and Bending Characteristics
The braided structure gives the product excellent flexibility, allowing for large-angle bends from 0-180°. The minimum bending radius is only 3 times its own thickness, adapting to complex spatial layouts and the dynamic connection needs of moving parts in equipment.
02
Vibration and Fatigue Resistance
The flexible structure of the copper wire braid absorbs the vibration impact and thermal expansion and contraction stress generated during equipment operation, avoiding breakage and loosening problems caused by stress concentration in rigid connections, thus improving long-term operational reliability.
03
Low Contact Resistance Connection
Both ends employ an integrated crimping process, ensuring a tight fit between the terminals and the braided conductor. The contact resistance is stable and extremely low, ensuring unimpeded power transmission and reducing heat loss.
04
Quick installation and adaptation
The modular terminal design, combined with precisely positioned mounting holes, eliminates the need for complex bending processes, enabling direct and rapid assembly to meet the needs of on-site equipment installation and subsequent maintenance.
05
Manufacturing Advantages and Production Processes: The Art of Weaving, the Science of Crimping
Our core competitiveness lies in the precise control of "flexibility."
Precision Bundling and Weaving: We employ high-precision, high-speed braiding machines to precisely control the tension of each strand, the weaving angle (typically between 45° and 60°), and the weaving density. These parameters collectively determine the product's flexibility, current-carrying area, and mechanical strength. We can customise the most suitable weaving parameters according to customer needs.
Non-destructive Terminal Connection: The connection between the terminal and the braided tape is crucial. We use a large-tonnage hydraulic press with precision moulds for cold crimping or seamless connection using high-frequency induction welding. The entire process ensures:
Maximised Conductive Cross-Section: In the crimped or welded termination area, the copper wire and terminal form a metallurgical bond or intermolecular penetration, minimising conductive area loss.
Uniform Stress Distribution: A unique mould design ensures that the crimping force is evenly applied across the entire braided tape cross-section, avoiding localised stress concentration and ensuring the mechanical strength of the connection point.
Surface Treatment and Protection: Terminals are available with tin plating, silver plating, or nickel plating to meet different corrosion resistance and contact requirements. The braided tape itself can also be impregnated with insulating varnish or heat-shrink tubing to provide additional electrical insulation and physical protection.
Customized Dynamic Performance Configuration
Stiffness Gradient Design
Different braiding densities and layers are designed in different sections of the same Copper Braided Flat Tinned Cable for Power Transmission to achieve optimal flexibility and rigidity. For example, extreme flexibility near vibration sources and enhanced rigidity near equipment terminals ensure stable connections.
Multi-Path Redundancy Design
A broadband Flexible Copper Braid Busbar for Electric Furnace can be designed as multiple independently insulated braided strips connected in parallel, forming built-in current path redundancy. Even if a single strip malfunctions, the system can still operate at a derating rate.
Integrated Monitoring and Failure Warning
Optional embedded fiber optic sensors monitor the Copper Stranded Flexible Connection's bending curvature, temperature distribution, and abnormal vibration modes in real time, issuing warnings before physical failure occurs.
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