Flexible Busbar Connectors
Products Description
Unlike conventional cables or rigid busbars, this flexible busbar connectors uses multi-strand precision-drawn annealed round copper wire braided in a satin weave to form a conductor with three-dimensional adaptability. Its core technology lies in transforming the electromagnetic skin effect into an advantage-the diameter of a single filament is precisely controlled within the range of 0.15mm to 0.30mm, ensuring maximum current-carrying efficiency under power frequency and medium-to-high frequency operating conditions. The braiding angle has been optimized through finite element simulation, balancing longitudinal elongation and lateral torsional stiffness, allowing the product to maintain structural stability while retaining 15%-25% length redundancy.
Key Features:
Dynamic Compensation Capability: Absorbs thermal expansion and contraction displacement of ±20mm/m during equipment operation, preventing mechanical stress from being transferred to the braided copper busbar customizable fixing points.
Maintenance-Free Interface: Molecular-level metal bonding technology eliminates the risk of contact resistance aging.
Spatial Freedom: Supports complex wiring with bending radii ≥ 5 times the braid width in three-dimensional space.
Core Technologies: Deeply Developed Conductive Connection Technology, Building a Solid Foundation for Performance
| Uniform Current Distribution Technology | Utilizing a "honeycomb braided structure," multiple strands of oxygen-free copper wire are interwoven at a specific angle, ensuring uniform current conduction within the braided layer. This avoids the "current concentration" phenomenon caused by traditional single-strand wires or simple braiding, reducing the risk of localized heating and improving current-carrying stability. |
| Balance Technology Between Mechanical Strength and Conductivity | Through "braid density gradient design," the braid density is increased in the connection areas at both ends of the connector to enhance mechanical fixing strength; the braid gap in the middle conduction area is optimized to ensure conductivity efficiency. This achieves a perfect balance between "flexible bending" and "rigid load-bearing capacity," solving the pain points of traditional flexible busbars, such as easy breakage and weak current-carrying capacity. |
| Corrosion-resistant Sealing Technology | The metal braided layer surface undergoes a "double-layer protective treatment": the inner layer is tin-plated (basic corrosion protection), and the outer layer can be gold-plated (for high conductivity/high corrosion environments) or nickel-plated (for wear-resistant/medium corrosion environments), depending on the application. The insulation layer uses an "integrated molding" process, resulting in seamless, bubble-free construction that prevents moisture and dust intrusion, enhancing protection levels and anti-aging capabilities. |
| Fatigue-resistant Vibration Technology | For dynamic operating conditions, the material toughness and braiding structure of the braided wires are optimized, enabling the connector to withstand over 10 million vibration shocks (frequency 10-2000Hz) while maintaining stable conductivity. The braided copper wire head and braided layer are double-fixed using "crimping + welding" to prevent detachment or poor contact due to vibration. |
Materials and Design Advantages: Good products begin with an obsession with detail
Materials Advantages:
Conductor: T2 high-purity oxygen-free copper (Cu≥99.95%), conductivity ≥98% IACS, an ideal medium for electrical energy transmission.
Connecting Pipes/Bars: Made of the same material as the conductor, ensuring electrochemical consistency and preventing potential difference corrosion.
Plating: Utilising high-purity silver, tin, and nickel, ensuring excellent conductivity, solderability, and corrosion resistance.
Design Advantages:
Stress Relief Design: In the connection transition area, we have designed a special curvature or reinforcing ring to effectively disperse stress concentration and prevent long-term fatigue fracture.
Optimised Contact Surface: The contact surface is machined and polished to ensure a smooth and flat surface, maximizing the effective contact area and reducing contact resistance.
Edible Installation Considerations: Offers various mounting hole positions and thread specifications, and can be customized to perfectly match your existing equipment.
Detailed Showcase and Professional Value
Conductor Structure Details
Our flexible braided conductors employ a multi-layered braided structure, with each layer precisely calculated to ensure uniform contact pressure between conductors during bending. This design not only improves conductivity but also effectively reduces contact resistance, preventing overheating issues caused by poor contact.
Insulation Layer Microstructure
The insulation layer utilises nanoscale composite materials with a unique microstructure. At the microscopic level, multiple microchannels are formed within the material, effectively guiding heat dissipation while maintaining excellent insulation performance. This design enables the braided copper ground wire to maintain stable performance even under high loads.
Connection Point Design
The connection points employ an innovative dual-contact design, ensuring stable electrical connections under any angle and pressure. Even in vibrating environments, copper stranded wire maintains low contact resistance, avoiding the loosening problems common in traditional connection methods.
Standardized Interfaces
We offer standardised interface designs compatible with mainstream power equipment. We also provide customised services, designed to meet specific customer needs and ensure a perfect match between the flat copper braided wire and the customer's system.
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