Braided Wire Copper BusBar
Braided wire copper busbar is a flexible conductive component formed by a precision braiding process using multiple strands of high-purity fine copper wires. In new energy inverters, energy storage battery packs, and rail transit traction systems, it is not only a channel for current transmission, but also a key engineering component that solves the problems of thermal expansion and contraction displacement, high-frequency mechanical vibration, and complex spatial layout that rigid connections cannot handle.
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Product Introduction
Braided Wire Copper BusBar are core flexible conductive components for high-voltage interconnection in the fields of new energy and power electronics. They are made of multiple strands of high-purity copper wire through precision braiding, integrated crimping, and insulated encapsulation. They combine the high current-carrying capacity of rigid copper busbars with the vibration resistance and fatigue resistance of flexible cables, enabling efficient conductivity, potential equalization, and mechanical stress buffering between high-voltage modules. This addresses the connection challenges in confined spaces and dynamic operating conditions. The products comply with standards such as IEC 61238 and GB/T 5585, are suitable for various new energy scenarios, and balance electrical and mechanical performance with engineering adaptability, providing core assurance for stable system operation.
Performance characteristics
High Conductivity, Low Power Consumption
Utilizes high-purity T2/TU1 copper (copper content ≥99.9%), with a conductivity ≥98% IACS and contact resistance ≤3mΩ, reducing transmission loss. The busbar flexible is compatible with 70V~1500VDC voltage and 50A~2000A current carrying capacity, meeting the high-voltage, high-efficiency transmission requirements of new energy sources.
Flexible and Vibration Resistant
Precision braiding of multi-strand copper wires ensures a bending radius ≤3 times the Braided Flexible Copper BusBar thickness. It boasts tensile strength ≥150MPa and withstands ≥1000 repeated bending cycles without breakage, absorbing vibration stress and making it suitable for vehicle-mounted, wind power, and confined space installations.
Weather-Resistant and Durable
Silicone rubber/fluoroplastic insulation encapsulation provides temperature resistance from -60℃ to 200℃, salt spray resistance ≥96h, and damp heat resistance ≥1000h. The Braided BusBar can withstand complex environments for extended periods without oxidation or delamination, ensuring long-term operation of new energy equipment.
Excellent Precision
Based on standardized production, the Braided Flexible Busbars Customized size tolerance is ≤ ±0.03mm, the weaving density deviation is ≤5%, the overall batch pass rate is ≥99.8%, the crimping and sealing are uniform, and it is suitable for batch assembly, effectively ensuring system stability.
Design Advantages
Flexible Structure Design
Precision braiding of multi-strand copper wires, with a bending radius ≤ 3 times the product thickness, allows for flexible bending, adapting to confined spaces and dynamic working conditions. This solves the pain points of rigid copper busbars, reduces engineering design and assembly difficulty, and improves selection adaptability.
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Integrated Structure Design
The braided layer and connectors are integrated and crimped, eliminating seams and preventing increased contact resistance. This simplifies the assembly process, improves efficiency, and meets the needs of batch assembly in engineering projects, effectively reducing labor costs for Flexible Braided Copper Busbar.
02
Customizable Design
Supports customization of specifications, connectors, surface treatments, and insulation materials based on customer PDF/CAD/3D drawings, precisely matching equipment requirements. No design adjustments are needed from the customer, significantly improving Braided BusBar selection convenience and adaptability.
03
Environmentally Resistant Design
Silicone rubber/fluoroplastic insulation and high-purity copper conductors make Flexible Insulated Copper Busbars suitable for a wide temperature range of -60℃ to 200℃ and complex working conditions. No additional protection is required, effectively reducing engineering operation and maintenance costs.
04
Lightweight design
Compared with traditional rigid copper busbars, the product weight is reduced by more than 30%, balancing current carrying capacity and mechanical strength, reducing equipment weight, and making it suitable for weight-sensitive scenarios such as new energy vehicles, meeting the requirements for lightweight selection.
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Why choose us
Choosing us guarantees a combination of product and company advantages, precisely meeting the engineering procurement and technology selection needs of the new energy and power electronics fields. Our Braided Wire Copper BusBar utilize high-purity T2/TU1 copper, boasting core advantages such as high conductivity, low power consumption, flexibility, and vibration resistance. Customization is available to meet industry standards, and multiple tests ensure stable operation. As a group enterprise, we possess ample production capacity and strong technical capabilities. Our technical backbone originates from Xiamen Hongfa Group, and we have a global localized service network, providing rapid response, one-stop procurement, and full-process technical support. We comprehensively mitigate procurement risks, safeguarding engineering projects.
Contact Us
For Braided Wire Copper BusBar samples, customized solutions, or technical consultation, please feel free to contact us. We provide professional support throughout the entire process of your engineering procurement and technology selection.
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