Flexible Copper Braided Wire Connectors With Welded Ends
Products Description
Flexible Copper Braided Wire Connectors with Welded Ends are flexible conductive components. Their key feature is that they combine the excellent electrical conductivity of copper with a structural design-achieved through a specialized braiding process-that allows for flexibility and movement.
The product primarily consists of the following components:
A main body of highly conductive braided copper wire
Precision-welded terminals
Connection holes or mounting areas
Surface treatment layer (selected based on application requirements)
The multi-strand braided copper structure enables the product to withstand repeated bending and the micro-vibrations generated during equipment operation, all while maintaining stable electrical performance.
Application Advantages: Superior Performance in Specific Scenarios
New Energy Vehicle Industry
Serves as an equipotential connection between battery modules and pack housings, or as a high-frequency grounding cable for motor controllers. Its lightweight nature contributes to overall vehicle weight reduction while withstanding the prolonged, high-frequency vibrations found within battery packs.
Power Transmission and Distribution Systems
Used for expansion joint connections in equipment such as transformers, switchgear, and circuit breakers. Copper Braided Flex Connectors effectively absorb mechanical shocks from switching operations as well as displacements caused by thermal expansion and contraction, protecting expensive electrical equipment from damage due to mechanical stress.
Rail Transit and Heavy Machinery
In applications such as high-voltage cabinets for locomotives and crane motor connections, Braided Copper Flexible Connector With Tin Ends demonstrate exceptional fatigue resistance, withstanding millions of vibration cycles without loosening.
Manufacturing Process
Raw Material Selection
We select high-conductivity oxygen-free copper wire and subject the Copper Braided Flexible Busbar Connector to an annealing process to enhance flexibility and braiding performance.
01
Precision Braiding
Automated braiding machines produce flat or round braided structures based on preset parameters, ensuring uniform tension control.
02
Terminal Welding
Following surface cleaning, specialized welding equipment is used to form an integrated terminal, followed by heat treatment to relieve internal stress.
03
Post-processing and Protection
Options include surface plating and the application of insulating sleeves or protective sheaths, tailored to specific requirements.
04
Comprehensive Testing
Copper Braided Connector for New Energy Vehicles undergo multiple quality checks, including conductivity testing, tensile strength testing, flexural fatigue testing, salt spray corrosion testing, and electrical aging verification.
05
Detailed Features: Key Engineering Considerations
Braided Body Surface: Features a uniform, tight weave free from defects such as broken, loose, or skipped strands. The surface is smooth and clean with consistent spacing between copper strands, ensuring uniform current distribution throughout the braid for Laminated Copper Braided Copper Busbar.
Welded Terminal Interface: The weld zone is dense and free of porosity, cracks, or oxidation layers. Terminal flatness is achieved via precision CNC milling, maintaining a tolerance of ≤0.02mm. Contact surfaces undergo ultrasonic cleaning and mechanical polishing, resulting in a surface roughness of Ra ≤0.8μm.
Transition Zone: A smooth transition exists between the braided body and the terminal, eliminating steps, sharp edges, and stress concentration points. A flared design prevents the braided strands from being sheared by the terminal edge during bending.
Mounting Holes: Precision-machined according to customer drawings with strictly controlled positional accuracy, ensuring precise and convenient on-site installation.
100% Electrical Performance Testing: Every unit undergoes a continuity test at 500V, with contact resistance ≤5mΩ. X-ray inspection covers 100% of the weld zone to guarantee zero-defect weld quality.
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If you are selecting components for new energy, power equipment, or industrial connection systems, we can provide tailored Copper Braided Connector for New Energy Vehicles solutions based on your structural drawings, electrical specifications, and operating environments. Leveraging our engineering expertise and robust manufacturing capabilities, we help customers enhance product reliability and improve project delivery efficiency.
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