Copper Braided Connector For New Energy Vehicles
Products Description
The Copper Braided Connector for New Energy Vehicles is a heavy-duty, flexible conductive component created by combining multiple strands of fine copper wire through a specialized braiding process and securing the ends via high-density, solid-state crimping.
Multi-dimensional flexible compensation: Unlike laminated copper foil connectors that bend in only one direction, the braided structure offers omnidirectional physical flexibility. It not only accommodates displacement across the X, Y, and Z axes but also easily handles complex installation requirements involving torsion and misalignment.
Resistance to high-frequency dynamic fatigue: Vehicles generate continuous, low-amplitude, high-frequency vibrations during operation. This braided connector acts as a vibration damper, absorbing and dissipating mechanical energy through its own deformation and effectively breaking the vibration transmission path between powertrain components.
Application Advantages: Comprehensive Coverage of New Energy Vehicle High-Voltage Systems
Internal Battery Pack Module Connections
Used between cell modules and between modules and the Battery Disconnect Unit (BDU), these Braided Flexible Power Shunts absorb stresses caused by cell expansion and accommodate tight assembly spaces, making them the preferred internal connection solution for high-capacity power battery packs.
High-Voltage Power Distribution Units (PDU/BJB)
Serving as flexible links between main contactors, pre-charge circuits, and fuses, they absorb mechanical shocks from relay operations and facilitate compact, reliable internal wiring.
Motor Controllers and Drive Motors
Connecting the inverter outputs to the motor stator terminals effectively isolates the controller from high-frequency mechanical vibrations originating from the motor, thereby protecting sensitive internal electronic components.
Vehicle Grounding and Equipotential Bonding
Used for equipotential bonding between the battery pack housing, motor casing, and vehicle chassis, these connectors prevent electric shock risks associated with high-voltage leakage and provide a low-impedance path for fault current dissipation.
Detail Showcase: Quality Rooted in Precision
| Rounded Terminal Edges | All stamped terminal edges undergo deburring and rounding processes to prevent finger injuries or damage to the insulation of surrounding wire harnesses during installation and tightening. |
| Smooth Transition Zones | We pay special attention to the transition area between the braided strap and the terminal crimp zone. This area is specially formed to eliminate loose or protruding strands ("wire flare"), ensuring a tight fit for the insulation and preventing corona discharge. |
| Traceability Markings | QR codes or batch numbers are stamped or laser-engraved in a prominent location on the terminal. Through the MES system, customers can trace raw material batches, production equipment IDs, and inspector details, meeting IATF 16949 quality traceability requirements. |
| Customized Insulation | In addition to standard PVC tubing, we offer high-temperature resistant (180°C+) silicone rubber and fiberglass tubing, as well as abrasion-resistant corrugated sleeves, designed to withstand harsh environments such as chassis scraping or proximity to high-temperature exhaust systems for Grounding Flexible Tinned Connection Copper Braided. |
Material Advantages
Conductor Material-T2 Oxygen-Free Copper: With a copper content of ≥99.95% and electrical conductivity of ≥98% IACS, this is the conductor material offering the best overall performance for power transmission. Its advantages include: high conductivity ensuring minimal energy loss during transmission; excellent ductility enabling fine-wire drawing and precision braiding; and stable physical properties that maintain low resistance across a wide temperature range.
Surface Treatment Layers: A tin-plated layer (thickness ≥8 μm) provides oxidation and corrosion protection, withstanding over 48 hours of salt spray testing without rusting; a silver-plated layer further enhances conductivity, making it suitable for high-frequency or high-temperature applications, or scenarios requiring extremely low contact resistance.
Terminal Material: Oxygen-free copper tubing or busbars-matching the material of the Laminated Copper Braided Copper Busbar-are used to ensure the absence of potential differences and electrochemical corrosion risks throughout the conductive circuit.
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As a critical flexible connection component within the high-voltage electrical systems of new energy vehicles, the Laminated High Current Copper Wire Braided Flexible achieves an optimal balance of electrical conductivity, mechanical reliability, and installation flexibility through its braided copper structure, highly conductive materials, and precision manufacturing processes.
For manufacturers of new energy vehicles, battery systems, and energy storage equipment, high-quality copper braided connectors not only enhance product safety but also assist engineering teams in optimizing structural designs, simplifying assembly, and improving the long-term operational reliability of the entire system.
If you are developing battery systems or high-voltage connection solutions for new energy vehicles, we can leverage our proven capabilities in copper processing, braiding, and custom development to provide engineered connection solutions tailored to your specific application requirements.
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