Copper Braided Flexible Shunt
Products Description
Unlike traditional rigid copper busbars or wires, the core of Copper Braided Flexible Shunts lies in their dual properties of "conductivity + buffering." Their structure consists of multiple strands of fine copper wires precisely braided into a mesh conductor, with terminal connection areas formed at both ends through crimping, welding, or integral molding.
This structure brings several essential characteristics:
Multi-point conductive paths: The braided structure forms distributed current channels, reducing the risk of localized overheating.
Excellent flexibility: Can be bent in multiple directions without metal fatigue fracture.
Strong vibration resistance: Maintains stable contact under high-frequency mechanical vibration environments.
Low contact resistance: The terminal area is high-voltage molded, ensuring a stable and reliable electrical connection.
From an engineering perspective, this type of product is essentially a combination of "electrical connector + structural compensation component."
Manufacturing Advantages: A Craftsman's Chain from Raw Materials to Finished Products
Independent Wire Drawing and Annealing Process
Through online annealing, we precisely control the elongation and hardness of the copper wire, ensuring that the Flexible Busbars have sufficient tensile strength without being too brittle and breaking under long-term vibration.
Precision Braiding Matrix
Utilizing multi-head fully automated braiding machines, we ensure uniformity of braiding angles. This consistency is not only aesthetically pleasing but also guarantees even load distribution throughout the connector under tension.
Diverse End Treatments
Equipped with industry-leading large-tonnage stamping equipment and an ultrasonic metal welding laboratory, we can provide customized services for irregularly shaped ends, bevel cutting, and 3D bending pre-forming, all based on customer drawings.
Detailed Highlights
Braided Tape Width and Thickness
Braided tape widths range from 5mm to 100mm, and the thickness can be adjusted according to the number of layers. Wide, thin Tinned Copper Braid Earthing Tape is suitable for scenarios requiring a large contact area, while narrow, thick braided tape is more suitable for installation environments with limited space.
Custom Terminals
The shape, size, and drilling position of terminals can all be customized according to customer drawings. Whether it's a round hole, square hole, or irregularly shaped hole, they can all be machined in one go on a precision mold, ensuring installation accuracy.
Optional Insulation
For applications requiring additional electrical isolation, heat-shrinkable insulating sleeves or rubber sheaths are available. Insulation levels can be selected according to usage requirements.
Identification and Traceability
Each Tinned Copper Braid Wire Grounding Jumper can be laser-engraved with identification information, including model number, batch number, production date, etc., upon customer request, facilitating on-site installation identification and subsequent maintenance management.
Application Advantages: Empowering All-Scenario Practical Applications in Complex Industrial Scenarios
| New Energy Storage and Inverter Systems | Energy storage containers have compact interiors, and battery modules experience slight volume expansion during charge-discharge cycles. Our Flat Copper Braid Flexibles absorb this micro-deformation, while their high-density braided structure effectively resists the high-frequency harmonic magnetic fields generated by the inverter, ensuring lossless energy transmission from the DC to AC side. |
| High-Power Rectification and Metallurgical Electrochemistry | In ultra-high current conditions such as aluminum electrolysis and electroplating, where tens of thousands of amperes are often involved, the heat generated by the busbars is extremely high. Our multi-layered, ultra-wide braided strips, combined with a water-cooled terminal design, not only provide ultra-large cross-section current channels but also, through their flexibility, completely release the thermal expansion stress of the Braided Flexible Copper BusBars, which can extend for several meters, preventing the catastrophic consequences of the busbar supports being bent. |
| Rail Transit and High-Speed Rail Traction Systems | When trains travel at high speeds, there are complex relative displacements and severe vibrations between the car body and the bogies. Braided connectors here are not just conductors, but also a "lifeline." Their superior tensile and shear resistance ensures absolutely continuous and stable traction current, unaffected by wind, sand, rain, snow, and extreme temperature differences. |
| High and low voltage switchgear | At the connection between the moving and stationary contacts of circuit breakers and disconnectors, flexible braided strips serve as transition Copper Stranded Flexible Connection Customizeds, perfectly absorbing the enormous mechanical impact forces generated during switch opening and closing, extending the mechanical life of the contacts, and reducing maintenance frequency. |
contact us
If your project requires high current transmission and structural stress compensation, we can provide a tailored structural design and manufacturing solution based on your actual working conditions to help you achieve a better balance between reliability and installation efficiency for Copper Braided Connector Flexible Earthing Tape.
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