Laminated Copper Braided Copper Busbar
Products Description
Laminated Copper Braided Copper Busbars are essentially made by precisely braiding multiple strands of high-purity copper wire into a flat, flexible conductor, and then solidifying the ends or critical areas through a lamination process to form a rigid yet flexible electrical connection. It combines the extreme flexibility of braided structures with the low impedance characteristics of lamination technology, integrating high current carrying capacity, mechanical buffering, electromagnetic optimization, and insulation protection to create a power transmission path adaptable to complex operating conditions.
Key features include:
Composite braided laminated structure: High-density braiding of fine copper wires forms a flexible body. At the same time, the ends or local areas are laminated and solidified to form a rigid mounting surface, achieving a perfect balance between flexible buffering and reliable fixation.
Multi-dimensional bending adaptability: Supports multi-directional bending, torsion, and stretching, easily coping with equipment vibration, thermal expansion, and installation deviations.
Detailed Showcase: Meticulous Engineering Dedication
| Monofilament Anti-Scattering Chamfering and Rounding | The cut surface of the braided tape is a weak point prone to monofilament scattering and tip discharge. We employ a proprietary end-melting anti-scattering process and full-rounded corner polishing to completely eliminate microscopic burrs, ensuring the insulation safety of high-voltage systems and a smooth assembly feel. |
| Customized End Hole Types and Anti-Rotation Bosses | Ends support countersunk holes, blind holes, oblong holes, and threaded inserts to meet various fastening requirements. For high-current vibration scenarios, custom anti-rotation bosses and locating pin holes can be provided to ensure uniqueness and prevent loosening during installation. |
| Layered Insulation and Localized Heat Shrink Tubing | For multi-layered laminated structures, we offer customized interlayer insulation and overall heat shrink tubing. Using high-polymer flame-retardant heat shrink tubing, shrinkage is performed through precisely controlled drying tunnels to ensure the insulation layer tightly conforms to the contours of the braided tape, without air bubbles or dead corners. |
| Laser traceability and full life cycle record | Each laminated braided busbar is equipped with a laser-engraved unique QR code at its end, enabling full-process data traceability from single filament batch, braiding parameters to crimping pressure curve, meeting the stringent quality control audit requirements of automotive and power grid grades. |
Production Process Visualization
Copper Wire Annealing
Copper wire must undergo vacuum annealing before weaving, with a Vickers hardness HV≤65 to ensure flexibility.
01
Online Weaving Inspection
During the weaving process, a laser diameter gauge is used to continuously monitor the external dimensions.
02
Ultrasonic Testing of Laminated Sections
10% of the laminated ends in each batch are randomly sampled and ultrasonically scanned to determine if there is delamination or voids inside.
03
Pull-off Force Test
On the sample, the laminated ends are fixed, and an axial tensile force is applied to the braided section.
04
Temperature Rise Cycling Verification
With the rated current applied, 1000 cycles of heating to 120℃ and then naturally cooling to room temperature are performed. The initial and final end temperature difference is measured to be ≤5℃.
05
Application Advantages: Diverse Coverage, Scenario-Enabling
New Energy Vehicles and Energy Storage Systems
Copper Braided Busbar Electrical Flexible Wire Cables between battery modules and between modules and high-voltage power distribution units, adapting to vibration and thermal cycling conditions.
01
Rail Transit and Heavy Industrial Equipment
Traction systems, auxiliary power supplies, and grounding connections, provide a highly reliable vibration-resistant path.
02
Industrial Automation and Switchgear
Copper Braided Ground Strap Wire Cables in inverters, bus trunking, and UPS systems, simplify assembly and improve anti-interference capabilities.
03
New Energy Power Generation Facilities
Internal connections in inverters, combiner boxes, and wind/photovoltaic equipment, ensure long-term outdoor stability.
04
contact us
Whether it's new energy vehicle battery systems, energy storage equipment, or high-voltage power control systems, we can provide you with one-stop engineering support, from design optimization and Copper Braided Flexible Busbar Connector development to mass production, based on current carrying requirements, installation environment, and structural space, helping projects complete verification and achieve stable mass production more quickly.
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