Flat Copper Braided Flexible Connectors
Flat copper braided flexible connectors are flat flexible power transmission core components designed specifically for high current, high vibration, and complex installation conditions. They are interwoven with multiple strands of fine copper wire through precision weaving technology to form a tightly ordered flat mesh structure. Customized copper connection terminals are integrated at both ends, perfectly integrating the excellent conductivity of high-purity electrolytic copper with the mechanical flexibility of the weaving structure. They are the best alternative to traditional rigid copper bars under dynamic conditions.
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Product Introduction
In today's transition from "functional implementation" to "space efficiency and dynamic reliability" in electrical engineering, the available space inside equipment is becoming increasingly precious, while dynamic loads and vibration environments are becoming more stringent. Flat copper braided flexible connectors were born for this purpose - they retain the flexibility and seismic advantages of circular braided busbars, while further reducing installation height requirements with a flattened structure, making them an ideal interconnect component for high-density power electrical systems.
Manufacturing process
Precision weaving process
Numerous fine copper wires are interwoven with each other in a specific weaving method to form a tight and orderly flat mesh structure, strictly controlling the weaving density within the range of 80% -95%. This process endows Flat copper braided flexible connectors with excellent flexibility, allowing them to be freely bent.
Terminal integration process
The braided tape of Flat copper braid flexible is firmly bonded to the copper terminal at both ends through crimping or welding processes, forming a low resistance, fatigue resistant connection end that can withstand long-term vibration and mechanical stress, avoid problems such as end detachment.
Full process quality control
From copper wire drawing, weaving forming to terminal processing, the entire process detects core indicators such as weaving density, resistance value, mechanical strength, etc., to ensure that each Flexible braided custom connector meets electrical industry standards and is suitable for various harsh working conditions.
Application scenarios
new energy vehicle
Braided copper wire is used to connect the battery module and drive system of electric vehicles, adapting to the compact space inside the battery pack and the vibration environment during driving.
01
rail transit
Applied to the electrical connection between train traction inverters and motors, adapting to the vibration and narrow equipment compartment space during high-speed operation.
02
Industrial Automation
Braided wire flexible copper is used to connect power supplies, controllers, and motors for industrial robots and automated production lines, enabling dynamic wiring requirements.
03
Power equipment
Flexible braided copper busbar is used for connecting transformer output terminals, absorbing thermal expansion displacement, and adapting to compact spaces inside distribution cabinets.
04
Material advantages
conductivity
High purity electrolytic copper has extremely low electrical resistivity (≤ 0.017241 Ω· mm ²/m), ensuring minimal power loss during transmission, especially suitable for high current, long-distance, or high-frequency on-off scenarios.
corrosion resistance
Copper material itself has good antioxidant capacity and can maintain the stable conductivity of Copper braided flexible busbar for a long time in conventional industrial environments, reducing the problem of increased contact resistance.
ductility
High purity copper wire is not easily broken during the weaving process, and can support finer wire diameters and higher weaving densities, thereby enhancing the flexibility and current carrying capacity of Flat copper braided flexible connectors.
Thermal conductivity
The high thermal conductivity of copper helps to quickly dissipate Joule heat generated at connection points, reduce local temperature rise, and extend the service life of the insulation layer and peripheral components of Soft bare copper wires.
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