Flexible Braided Wire

 

The conductor material determines both electrical loss and mechanical behavior. Apollo uses high-purity electrolytic copper for flexible braided conductors, with material selection based on conductivity, strand diameter, required flexibility, and operating environment. C1100 or equivalent high-conductivity copper can be considered where low electrical resistance is a primary requirement.

Unlike a rigid copper bar, a braided conductor contains multiple fine copper strands working as parallel current paths. The number of strands, individual wire diameter and braid density affect the conductor's cross-sectional area, flexibility and heat dissipation. These parameters should therefore be specified together with continuous current, peak current, ambient temperature and allowable temperature rise.

Tinned copper is available for environments where oxidation resistance and stable terminal contact are required. Bare copper can be used where the installation environment and maintenance conditions permit exposed copper.

The braid is formed under controlled tension to maintain consistent width and density. Terminal geometry is developed according to the mounting hole, bolt size, contact area, and available installation envelope.

For applications requiring a rigid-to-flexible transition, Apollo can combine braided copper conductors with stamped copper terminals or welded connection ends.

 

 

Engineering Parameter	Available / Typical Configuration
Conductor Material	High-purity electrolytic copper
Copper Grades	C1100 / T2 / equivalent copper
Conductor Structure	Multi-strand braided copper wire
Surface Condition	Bare copper / tin-plated/silver-plated
Braid Density	Controlled according to flexibility and current requirements
Conductor Cross-Section	Calculated according to continuous and peak current
Terminal Material	Copper/copper alloy according to application
Terminal Forming	Stamping/cutting/forming
Terminal Joining	Resistance brazing/diffusion welding / ultrasonic welding
Dimensional Control	Drawing-based inspection
Electrical Verification	DC resistance/continuity testing
Insulation Option	Fiberglass sleeve / protective tubing
Application	EV / ESS/switchgear/transformer / industrial equipment

 

Engineering note: Current carrying capacity should not be selected from conductor cross-section alone. Continuous current, duty cycle, ambient temperature, mounting condition, and allowable temperature rise should be evaluated together.

 

 

For a flexible braided connection, the transition between the woven conductor and terminal is a primary mechanical and electrical interface. Apollo selects the joining process according to copper thickness, terminal geometry, required conductivity, and mechanical loading.

 

Resistance brazing can be used for copper braid and terminal assemblies where localized heating and repeatable joint formation are required. Diffusion welding is suitable for configurations requiring a compact solid-state electrical interface. Ultrasonic welding can also be considered for selected fine-strand copper assemblies where low thermal input is preferred.

 

Terminal dimensions are controlled to maintain the required contact area and mounting geometry. The finished assembly can include drilled or stamped mounting holes, formed terminals, and additional protective structures.

 

For corrosive or humid environments, tin plating can reduce copper surface oxidation and support more stable contact performance. Silver plating may be considered where the electrical interface requires improved surface conductivity under specified operating conditions.

 

Where the braided conductor requires additional mechanical or thermal protection, fiberglass insulation sleeves or other protective tubing can be added without restricting the required flexing movement.

 

 

Quality control for Flexible Braided Wires covers the conductor, braid geometry, terminal connection, and final electrical performance rather than only visual appearance.

 

Incoming copper material is checked against the specified material grade and documentation. During braiding, production controls focus on conductor strand arrangement, braid width, density, and overall dimensional consistency.

 

For terminal assemblies, inspection can include mounting-hole dimensions, terminal thickness, joining position, joint appearance, and mechanical integrity. Electrical checks can verify continuity and DC resistance against the approved drawing or customer specification.

 

For projects requiring higher process documentation, Apollo can support PPAP Level 3 documentation with process flow, PFMEA, Control Plan, material certificates, and CPK process capability data.

 

The quality system is operated under ISO 9001 and IATF 16949 requirements for applicable automotive production. Inspection equipment can include CMM measurement systems and optical measurement equipment for dimensional verification.

 

Recommended validation items for a flexible braided connection include:

Conductor resistance

Terminal contact resistance

Braid width and thickness

Terminal dimensional accuracy

Joint integrity

Plating thickness where specified

Temperature-rise testing

Mechanical pull or tensile testing

Flexing or vibration validation according to application requirements

 

For EV and ESS programs, validation conditions should be defined from the actual operating profile rather than applying a generic test value to every connector configuration.

 

 

 

 

For a new EV, ESS, switchgear, or industrial power connection, send Apollo your 2D/3D CAD drawing (.STEP, .DWG), current requirements, or electrical parameter list.

 

Include continuous/peak current, conductor length, installation space, terminal dimensions, operating temperature, and movement or vibration conditions where available. Apollo's engineering team can review the conductor structure, braid density, terminal configuration, and joining method and provide a free DFM manufacturability analysis within 24 hours, followed by a factory-direct quotation.