Copper Braided Connectors With Welded Ends
Products Description
Copper Braided Connectors with Welded Ends are premium flexible conductive components engineered for reliable high-current connections across diverse industries. Crafted from high-purity T2 oxygen-free copper, these connectors feature a braided structure that delivers exceptional flexibility, allowing them to absorb vibration and compensate for displacement in dynamic applications. The welded end design ensures robust, low-resistance contact, enhancing conductivity and long-term stability.
Available with multiple surface treatments-including tin, silver, and nickel plating-they offer superior corrosion resistance and adaptability to harsh environments, from industrial workshops to outdoor renewable energy setups. As a versatile solution, they serve as essential parts in power systems, new energy vehicles, electrolyzers, rail transit, and photovoltaic/wind power equipment. Combining durability, efficient current transmission, and easy installation, Soft Bare Copper Wires stand out as a trusted choice for projects requiring consistent performance and flexibility.
Raw Material Specifications
Copper Purity
Braided Copper Wire's copper ≥99.95%, with total impurities ≤0.05% (Fe ≤0.005%, Pb ≤0.005%) to ensure stable conductivity.
Single Wire Specifications
Braided Flexible Busbar standard 0.15 mm diameter (optional 0.05 mm–0.25 mm), with a tensile strength of ≥200 MPa and elongation ≥30%.
Braided Base Material
Flexible Braided Copper Busbar woven via 8-spindle/16-spindle braiding machines at a density of ≥90%, balancing flexibility and current-carrying capacity.
Production Process & Parameter Control
| Weaving Process | Flexible braided copper busbar equipment: 16-spindle high-speed braiding machines operating at 300 r/min. Control Indicators: Braiding angle 45° ± 5°, width tolerance ≤ ±0.5 mm, length tolerance ≤ ±1 mm. |
| Welded End Treatment | Copper Braided Wire process: Medium-frequency induction fusion crimping (replacing traditional cold crimping), with welding temperature 800°C ± 50°C and crimping force ≥100 kN. Performance: Weld tensile strength ≥150 MPa, conductor-terminal contact area ≥95%. |
| Post-Processing | Flex bus bar shaping: CNC milling for precision finishing, terminal flatness tolerance ≤0.02 mm. Deburring: Ultrasonic cleaning + mechanical polishing, surface roughness Ra ≤0.8 μm. Inspection: 100% continuity testing (500V voltage, resistance ≤5 mΩ), X-ray flaw detection (100% weld defect detection rate). |
Application Scenarios
Power Systems
Flexible Braided BusBar in transformer bushing-busbar connections, high/low-voltage switchgear.
Parameter Matching: Cross-sectional area 100–300 mm², current-carrying capacity 125–1,300 A, temperature resistance -40°C to 150°C.
New Energy Vehicles
Soft Bare Copper Wires in battery module connections, motor stator outlet terminals.
Parameter Matching: Cross-sectional area 10–50 mm², bending life ≥10,000 cycles (10× width radius), weight ≤50 g/piece.
Electrolysis/Plating Industry
Braided Copper Wire in electrolyzer anode-busbar connections.
Parameter Matching: Cross-sectional area 500–2,000 mm², current-carrying capacity ≥5,000 A, tin-plating thickness ≥3 μm.
Rail Transit
Copper Braided Connectors with Welded Ends in pantograph grounding, traction converters.
Parameter Matching: Vibration resistance 50–2,000 Hz, tensile strength ≥200 MPa, flame retardant rating UL94 V-0.
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