Flat Braided Copper Flexible Connector
Products Description
Flat braided copper flexible connectors are essentially multi-strand parallel conductive structures. Through a flat braiding process, current is distributed over a larger surface area, effectively reducing the skin effect and localized temperature rise.
Their structural characteristics determine the following core advantages:
Excellent lateral flexibility and longitudinal stability
Large current transmission can be achieved within a limited space
Effective absorption of vibration, displacement, and thermal stress during equipment operation
Compared to circular flexible connectors or single conductors, flat braided structures offer superior performance in heat dissipation, installation adaptability, and long-term reliability.
Innovative Technological Features: Scenario-Based Technological Breakthroughs Adapt to Diverse Needs
Precision Braiding Technology
Utilizing a multi-spindle (24-spindle, 36-spindle, 48-spindle) layered braiding process, we use automated equipment to precisely control the braiding density and texture, ensuring uniform copper wire distribution and balanced stress. This technology not only improves the Flexible Busbar's flexibility and fatigue resistance but also ensures the stability of conductivity, avoiding problems such as excessive local resistance and abnormal heating caused by uneven braiding.
Integrated Joint Welding Technology
Abandoning traditional crimping processes, we employ advanced resistance welding technology to achieve a fusion-bonded connection between the braided copper strip and the joint. By precisely controlling the welding current and pressure, gaps between the joint and the copper strip are eliminated, improving connection reliability, preventing joint loosening due to long-term vibration, and significantly extending the Tinned Copper Braid Earthing Tape's service life under dynamic operating conditions.
Fatigue Resistance Enhancement Technology
Targeting high-frequency vibration scenarios such as new energy vehicles and rail transportation, the product's fatigue resistance is improved by optimizing the braided structure and material heat treatment process. After multiple bending and vibration tests, the Flat Copper Braid Flexible maintains structural integrity and stable conductivity, effectively solving the pain point of traditional flexible connectors being prone to fatigue fracture.
Main Functions and Application Advantages
Flexible connection between transformers and instrument transformers
Transformers generate significant noise and vibration during operation. Flexible connectors effectively interrupt the mechanical transmission of vibration, protecting porcelain bushings from breakage and reducing noise levels.
Grounding systems and lightning protection
As the primary grounding wire, its high conductivity and flexibility allow for easy connection between equipment casings and the earth. In the event of a short circuit, Braided Connectors can withstand instantaneous surge currents without melting.
Emergency Vehicles (EVs/ESS)
Within the battery pack, battery modules experience minute volume expansion. Braided Flexible Copper BusBars can adapt to these minute displacement changes, making them the preferred solution for internal electrical connections within the battery pack.
Switchgear and busbar trunking
Connecting circuit breakers to main busbars facilitates push-pull maintenance of circuit breakers without disassembling the fixed busbars.
Materials Science: High-Performance Copper Alloys Born for Dynamics
We have abandoned general-purpose soft copper materials and exclusively developed a high-fatigue-resistant copper-based composite material.
Microalloying Reinforcement Technology
We precisely introduce trace amounts of rare earth elements and reinforcing phases into an extremely high-purity oxygen-free copper matrix:
This significantly increases the recrystallization temperature and suppresses grain coarsening and softening under long-term high-temperature operation.
While maintaining conductivity >98% IACS, tensile strength and stress relaxation resistance are increased by more than 40%.
The material is isotropic, ensuring consistent performance in any bending direction.
Adaptive Oxidation Inhibition Layer
To address the oxidation problem of exposed copper surfaces, we have developed a self-healing passivation technology:
A slow-release antioxidant is added to the surface treatment solution, providing repair ions when micro-oxidation occurs.
This forms a dense and conductive passivation film, with dynamic resistance increasing by less than 70% in harsh environments compared to conventional Braided Tin Coated Copper Flexible Connectors.
contact us
Hot Tags: flat braided copper flexible connector, China flat braided copper flexible connector manufacturers, suppliers, factory, Lithium ion Batteries Connectors, Braided Flexible Busbar, Braided Connectors, Copper Tinned Wires, Grounding Braids Wire Tin Plated, braided copper wire
You Might Also Like
Send Inquiry