Braided Wire Flexible Copper
Braided Wire Flexible Copper utilizes high-purity copper wire braiding technology to provide superior electrical performance and flexibility, and is widely used in various fields such as new energy, rail transportation, and industrial automation. This product boasts extremely high shock resistance, excellent electrical performance, and long-term reliability, making it suitable for demanding power electronic systems, especially excelling in high-current transmission, complex wiring, and installation in confined spaces.
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Product Introduction
Braided Wire Flexible Copper is manufactured using a standardized precision braiding process. Conductor specifications can be flexibly adapted to current-carrying requirements, with braiding density controlled between 80% and 95%, balancing electrical performance and mechanical strength. The product can be bent and twisted at multiple angles, with a minimum bending radius suitable for wiring in confined spaces, solving the pain point of inconvenient installation of traditional rigid conductive components. It possesses excellent current-carrying capacity and low resistance characteristics, effectively reducing energy loss and skin effect during power transmission, and is suitable for long-term stable operation under complex working conditions.
Manufacturing technology
Copper Wire Pretreatment: High-purity copper wire is cleaned, dried, and straightened to remove surface oil, impurities, and oxide layers, ensuring a clean surface and uniform specifications, laying a solid foundation for subsequent braiding processes.
Precision Braiding: According to customized specifications and braiding density requirements, fully automated braiding equipment is used to braid the copper wire, strictly controlling the braiding density and precision to ensure the Flexible BusBar Manufacturers's electrical performance and flexibility meet the performance requirements of the selected project.
Precise Cutting: The braided copper wire is CNC-cut to control the cutting dimensional accuracy, ensuring precise matching of the Copper Braided Flexible Busbar with the installation space and terminal specifications, reducing on-site processing workload.
Surface Treatment: Depending on the operating conditions, the Copper Stranded Flexible Busbar undergoes electroplating treatments such as gold plating, silver plating, and tin plating to improve corrosion resistance and oxidation resistance, ensuring long-term product reliability.
Terminal Connection: Standardized welding processes such as laser welding and resistance welding are used to fix customized terminals to both ends of the Braided Copper Flexible Wire Connectors. The connection firmness is checked to ensure smooth current transmission and avoid engineering failures caused by poor contact.
Finished product finishing and inspection: The Braided Tin Coated Copper Flexible Wire Connectors edges are finished to remove burrs and sharp corners. Then, the product undergoes full performance and dimensional testing. After passing the test, the product is put into storage according to standardized packaging requirements and awaits delivery, ensuring that all products leaving the factory meet engineering application standards.
Product Parameters
| Parameters | Range/Value |
| Resistance | ≤0.07 Ω/m (25 mm², 20°C) |
| Current Carrying Capacity | 200–250 A (50 mm², 70°C) |
| Weave Density | 80–95% |
| Minimum Bending Radius | ≤10 mm (Total Thickness ≤3 mm) |
Main functions
High Current Carrying Capacity
Copper braided busbars offer excellent electrical performance, supporting high current carrying capacity. For example, a 50mm² copper braided wire can continuously carry 200-250A at 70°C, suitable for high-power electrical systems.
Superior Electrical Performance
Multi-strand copper braiding reduces resistance and skin effect, ensuring uniform current distribution, improving power transmission efficiency, reducing energy loss, and extending system lifespan for insulated flexible copper bars.
High Flexibility
Excellent flexibility allows for easy bending and installation in complex spaces, improving construction efficiency and adapting to various installation environments for Flexible Insulated Copper Busbars.
Strong Vibration Resistance
The braided structure absorbs vibration and impact stress, preventing connection damage and ensuring stable operation in high-vibration environments.
Long-Term Reliability
High-quality copper and refined processes improve Copper Stranded Flexible Busbar corrosion and oxidation resistance, reducing maintenance and replacement frequency and lowering long-term operating costs.
Quick Installation
No complex fixing processes are required, simplifying the installation process, saving time and costs, and making it suitable for scenarios requiring rapid response for Flexible Busbars.
Packaging and Transportation
- Small, standard items: Packed with inner plastic bags, inner cardboard boxes, outer cartons, outer pallets, and reinforced with outer moisture-proof film and cable ties. Multiple layers of protection effectively prevent scratches, oxidation, and moisture damage, suitable for small-batch, multi-specification deliveries, meeting the needs of small-batch trial production and multiple-batch procurement in engineering projects for Braided Wire Flexible Copper.
- Large, special items: Packed with inner pearl cotton, outer cardboard boxes, outer pallets, and reinforced with outer moisture-proof film and cable ties. Pearl cotton effectively cushions impacts during transportation, preventing product deformation and loosening of the weave. Suitable for large-batch, large-specification deliveries, ensuring the needs of batch assembly in engineering projects.
- Transportation: Utilizing professional industrial logistics service providers, the entire logistics process is traceable. Transportation methods are flexibly selected based on busbar flexible volume and delivery location. Domestic bulk orders can be delivered quickly, while cross-border orders rely on localized branches in Europe, the Middle East, Southeast Asia, and Northeast Asia to optimize transportation links, shorten delivery cycles, and ensure on-time delivery, meeting the needs of engineering procurement schedules.
Contact Us
If you are currently in the Braided Wire Flexible Copper selection or technology evaluation stage, you are welcome to provide project conditions and key parameters for engineering confirmation.
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