Flexible Copper Braided Wire Connectors With Welded Ends
Flexible Copper Braided Wire Connectors With Welded Ends are designed for high-current flexible electrical connections with low resistance, vibration resistance, and stable conductivity. The product features multi-strand copper braiding, welded terminal ends, optimized material selection, and precision manufacturing processes for EV, ESS, power distribution, and industrial electrical applications.
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Product Introduction
In high-vibration power distribution environments, thermal expansion and mechanical fatigue often cause rigid busbar connections to crack or loosen at contact faces. These Flexible Copper Braided Wire Connectors with Welded Ends use multi-strand C11000 OFE red copper wire (0.05mm–0.15mm strand diameters) in flat or round profiles to absorb dynamic structural movement. Terminals are unified into solid contact blocks via high-tonnage cold crimping or resistance press-welding, eliminating filler metal and extra contact resistance. Xiamen Apollo Stamping Welding Technology Co., Ltd manages full end-to-end processing-from precision braiding and press-forming to electro-tinning, silver plating, and custom PVC, PET, or silicone sleeving. Our engineering team provides complete DFM reviews to align cross-sectional area against continuous amperage specs for EV battery packs, transformers, and telecom grounding systems.
Technical Specifications & Material Standards
| Parameter Category | Technical Attribute / Specification | Base Material / Value Range | Engineering Standard | Testing & Quality Method |
| Raw Material & Purity | Conductor Base Wire Grade | C11000 / E-Cu High-Purity Red Copper (Cu ≥ 99.95%) | GB/T 5231 / ASTM B152 | Spark OES Chemical Analysis |
| Conductor Cross-Section | Standard Wire Gauges | 15 mm², 25 mm², 35 mm², 50 mm², 70 mm², 95 mm², 120 mm²+ | DIN 46433 / ISO 2768-m | Optical Microscope & Caliper Measurement |
| Strand Construction | Single Wire Diameter & Density | 0.12 mm strands; 80% – 95% Braiding Density | GB/T 5231 / ASTM B172 | Automated Wire Counter & Optical Density Check |
| DC Resistance | Electrical Resistance at 20°C | ≤ 0.07 Ω/m (25 mm² profile reference) | IEC 60028 | Micro-ohmmeter Resistance Check |
| Current Carrying Capacity | Continuous Operating Amperage | 200 A – 250 A (50 mm² profile @ 70°C working temp) | DIN 43671 / IEC 60512-5 | Continuous Temperature Rise Test |
Manufacturing Process & Thermal Management
Multi-Strand Wire Braiding
High-speed braiding machines weave 0.05mm–0.15mm tinned or bare C11000 copper strands into uniform, low-density weaves that maximize bend radius and fatigue life for Flexible Copper Braided Wire Connectors with Welded Ends.
Cold-Press Terminal Forming
High-tonnage mechanical presses compact the welded ends into exact rectangular geometries, stamping precise bolt hole profiles according to customer 2D prints for Copper Braided Ground Strap Wire Cable.
Electro-Plating Line
Inline electro-tin or silver plating creates a uniform, corrosion-resistant barrier over exposed terminal faces, preventing copper oxidation during high-temperature thermal cycles for Power Connector Flat Flexible Battery Braided Busbars.
Thermal Dissipation Geometry
The porous, flat-braid cross-section increases surface-area-to-volume ratio compared to solid bar stock, allowing forced air to cool the connector during continuous overcurrent surges.
Frequently Asked Questions
Q: Why choose welded ends instead of standard crimp terminals for Flexible Copper Braided Wire Connectors with Welded Ends?
A: Welded ends create a stable copper-to-terminal connection with controlled electrical resistance. They reduce strand loosening risks during vibration cycles and are suitable for EV battery packs, ESS systems, and high-current electrical assemblies.
Q: What quality documents can be provided for automotive supply projects?
A: The factory supports ISO9001 and IATF16949 Copper Braided Busbar Electrical Flexible Wire Cable production systems, with dimensional inspection reports, electrical test records, material certificates, and PPAP documentation available according to project requirements.
Q: Can the flexible copper braided connectors be customized for different current ratings?
A: Yes. The conductor cross-section, braid layers, terminal dimensions, welding method, and plating treatment can be customized based on current load, installation space, and thermal requirements provided by customer drawings.
Contact Us
Send us your 2D/3D CAD drawings (STEP, DWG, PDF) or current capacity requirements for a immediate DFM evaluation, terminal tooling plan, and factory-direct quotation within 24 hours.
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