Copper Braided Flexible Connector
As the core conductive connector of the new energy vehicle battery pack, the short Copper Braided Flexible Connector is a "flexible artery" between the battery cell pole and the high-voltage distribution module. Through a special stacking welding process, multiple layers of ultra-thin copper foil are integrated to achieve efficient power transmission and precise buffering of mechanical stress. Compared with traditional rigid busbars, it has excellent conductivity and bendability, which can adapt to complex wiring requirements in limited space of battery packs, while resolving the structural damage risk caused by vibration and temperature difference deformation during vehicle driving, providing key support for the safe and stable operation of high-voltage systems in new energy vehicles.
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Product Introduction
This series of Copper Braided Flexible Connectors is specially designed for the scenario of new energy vehicle battery packs. Unlike large soft connection products in the field of power electronics, it focuses on lightweight and high-reliability design, and can accurately match the integration needs of various power battery modules. It covers core scenarios such as cell series parallel connection, battery pack, and inverter connection in pure electric and hybrid vehicles, and is a key component for improving battery system energy density and extending cycle life.
specific parameters
Conductor specification
If T2 soft copper tape is used for the conductor of Copper Braided Flexible Connector, it can be divided into two types: bare copper and tin-plated copper. The standard specifications for copper strips include 9X0.8, 16X0.8, 20X1, 24X1, 32X1, 40X1, 50X1, 63X1, 80X1100X1, etc. The number of layers is between 2 and 12. If it is a soft copper bar used in automotive high-voltage battery packs, its conductor thin plate material is copper, the coating thickness is between sn0.5~1.0 ㎛, and the thickness is 0.25mm ± 0.02.
01
Insulation layer parameters
The insulation layer of Flexible Braided Custom Connectors mainly consists of two materials: special polyvinyl chloride (PVC) and thermoplastic elastomer (TPE). TPE has the characteristics of low smoke and halogen-free, and the insulation layer is mostly black or orange in color. In the application scenario of automotive high-voltage battery packs, the insulation sheath is made of TPE material. When ensuring fire resistance, mica tape containing soft mica with a thickness of 0.15mm is also used.
02
Production standard
There is no dedicated standard for Low to medium Voltage Flexible Connectors worldwide. The United States uses the UL758 electronic wire standard for production certification, while China usually refers to the GB/T5023 insulated cable standard and the UL758 electronic wire standard for production and manufacturing.
03
Current carrying capacity
Due to the skin effect, the multi-layered flat conductor structure of Braided Copper Wire allows the same cross-sectional area of the conductor to carry larger passing currents. Under the same current carrying capacity requirements, compared with ordinary round cables, Braided Flexible Busbar requires a smaller cross-section, which can effectively reduce the amount of conductor material used, reduce weight, and save layout space.
04
Application fields
new energy vehicles
Flexible Braided Copper Busbar is adapted to interconnect power battery modules, connect battery packs with high-voltage systems, respond to vehicle vibrations and spatial changes, and ensure stable power transmission.
Rail transit field
Braided Copper Bus Bar Heat Sink PVC Sleeves are used to connect pantographs with electrical equipment, traction converters with motors, withstand high-speed vibration and impact, and ensure electrical system stability.
Industrial automation field
Braided BusBar is compatible with automation equipment and production line electrical connections, with flexible wiring that breaks through rigid limitations and meets high-frequency operation requirements.
Why choose us
We always adhere to the original intention of quality, driven by technological innovation and guided by customer needs, continuously improving product performance and service quality, and committed to becoming a reliable partner in the field of new energy power connection. Choosing us means choosing customized product solutions and end-to-end peace of mind service guarantees that are tailored to the new energy scene, empowering efficient and long-term operation of new energy projects.
Our Partners
Our Copper Braided Flexible Connector partners span multiple industries, including automotive, electrical, and electronics, covering various regions worldwide, among which are renowned manufacturing enterprises. With stable product quality, flexible customized services, and efficient delivery guarantees, our products have gained widespread market recognition, earned unanimous praise from global partners, and accumulated a good reputation in the industry.
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