Copper Braid For Relay Applications
Products Description
Copper Braid for Relay Applications serves as a flexible conductive connector engineered specifically for magnetic latching relays. Constructed from high-purity electrolytic copper wire through precision braiding, it delivers consistent electrical conductivity and mechanical pliability during relay actuation. As an essential interconnect component, it finds extensive use in smart metering systems, electrical power infrastructure, and electric vehicles-playing a critical role in ensuring dependable relay switching while minimizing both contact resistance and thermal rise.
Product Features and Functions
Superior Flexible Conductivity
The professional copper braided wire employs a unique construction of stranded and interlaced copper strands, which functions as a flexible damper to absorb installation-related and operational vibrations and displacements-effectively insulating the relay's internal contact system from external physical damage.
Powerful Current Carrying Capacity
Through strategic enlargement of the Round Copper Braid's cross-sectional dimensions and strand density, substantial enhancement of current-carrying capability is achieved-rendering it well-suited for applications characterized by instantaneous high-current surges in smart metering systems and new energy infrastructure.
Excellent Heat Dissipation
Thanks to its porous construction, the Bare Copper Braid delivers superior heat dissipation through an expanded surface area-effectively lowering operating temperatures and prolonging equipment service life relative to conventional rigid copper busbars.
Material Performance and Advantages
| Material Parameters | Performance Indicators | Advantages |
| Material | Copper Stranded Wire uses 99.95% pure copper braid. | High conductivity, low resistance, oxidation resistance, and corrosion resistance. |
| Conductivity | ≥98% IACS. | Reduces current loss, reduces temperature rise, and improves energy efficiency. |
| Tensile Strength | ≥200 MPa. | Resists mechanical stress, preventing breakage of the Copper Stranded Wire due to frequent operation. |
| Temperature Range | -40℃ ~ +125℃ (bare copper) / +200℃ (with sheath). | Suitable for extreme environments, ensuring long-term stable operation. |
| Oxidation Resistance | Tin plating / nickel plating optional. | Delays oxidation and extends product lifespan. |
Manufacturing Process
Wire Drawing Process: Electrolytic copper is drawn into fine copper wires of 0.08–0.12mm to ensure uniform wire diameter.
Bragging Process: High-speed braiding machines intertwine multiple copper strands at a specific pitch to achieve the required density and flatness in the finished copper braided wire.
Terminal Welding: The copper terminals are joined to the braided wire using either resistance or ultrasonic welding. This ensures that the weld seams on the Flexible Copper Connector are characterized by complete fusion and are free from porosity.
Insulation Treatment: As required, a high-temperature resistant sheath is fitted and secured using heat-shrink or injection molding, which protects the insulation layer of the Copper Braid for Electrical Contact from being compromised.
Finished Product Inspection: Prior to shipment, every batch of Round Copper Braid must pass rigorous tests for conductivity, tensile strength, and temperature resistance. No batch is shipped unless it meets all specified requirements.
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Whether you are a manufacturer of magnetic latching relays, a smart meter manufacturer, or a partner in new energy vehicles and power systems, our Copper Braid for Relay Applications can provide you with a stable and reliable flexible conductive solution.
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