Copper Braided Flex Connectors
Products Description
Copper Braided Flex Connectors (also known as copper braided tape flexible connectors) are not simply stacked wire harnesses, but rather an integrated electrical compensation solution processed through precision braiding and pressure welding (or cold pressing).
Core Physical Properties:
Multi-directional Flexibility: Compared to foil connectors, the braided structure provides better omnidirectional torsional capability.
Dynamic Compensation: Optimized for absorbing mechanical shocks from reciprocating motion.
High-Efficiency Current Carrying: By optimizing the braid density, the effective conductive cross-sectional area is maximized while maintaining flexibility.
Design Flexibility
Customizable Geometry: Whether Braided Flexible Power Shunts' ultra-wide flat shapes, ultra-fine circular bundles, or pre-formed parts with special bending angles, we can achieve precise 1:1 customization.
Diverse Insulation Solutions: We offer a variety of protection options, including PVC dip coating, silicone tubing, heat shrink tubing, or braided fireproof mesh, to meet extreme temperature differences from -40°C to +150°C.
Deeply Matched to Application Scenarios
Switchgear and Busbars
Addressing the enormous impact forces during circuit breaker opening and closing, preventing loosening of fastening bolts.
Rail Transit
Coping with continuous high-frequency vibrations during locomotive operation, ensuring the power continuity of the traction system.
Electrolytic Metallurgy
Braided Copper Flexible Connector With Tin Ends Providing long-term stable conductive support through plating technology in high-current, strong acid corrosion environments.
New Energy Storage
Providing current transmission with minimal bending radius within a sealed battery cabinet, optimizing space utilization.
Manufacturing Advantages and Production Processes: Precision Manufacturing Through Weft and Warp
| Precision Coordination of High-Speed Spindle Braiding Machines | Our core production system originates from high-precision tubular braiding machines. Dozens of spindles (carrying copper wire spools) are driven by the main shaft, weaving at high speed along a complex "two up, two down" or "three up, three down" trajectory (a galloping spindle motion). The high rigidity of the equipment ensures constant tension during high-speed operation, avoiding the "loose band" phenomenon caused by uneven tension during weaving, ensuring absolute uniformity of density in every inch of the mesh. |
| Non-Destructive Pressing and Forming Process | End treatment is crucial to product lifespan. We have abandoned high-temperature brazing, which easily causes micro-cracks, and primarily adopt a high-tonnage precision cold pressing process. Through a specially designed gradient die, a huge radial extrusion force is applied to the ends of the braided wires inserted into pure copper or tin-plated copper tubing at room temperature. Under immense pressure, the copper tube undergoes plastic flow, mechanically interlocking with the microscopic protrusions on the surface of each internal copper wire, forming a highly airtight metallic bond. |
| Customized insulation and protection coating | After crimping, depending on customer requirements, the outer layer of the mesh can be sequentially coated with Teflon (PTFE) high-temperature insulating sleeves, fiberglass sleeves, or silicone tubes. These sleeves not only provide excellent electrical insulation performance but also prevent the woven mesh from being scratched by sharp metal edges or corroded by chemical gases in complex assembly environments for CU Flex Busbar. |
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If you are evaluating a high-reliability electrical connection solution, we can provide integrated design and manufacturing support tailored to your current load, structural space, and installation conditions, helping you achieve the optimal engineering solution between performance and cost for Flexible Copper Braided Connector Bus Bar.
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