Copper Braided Wire Flexible Connection Busbar Industry Knowledge

Copper braided wire flexible connection busbar, also known as copper braided wire flexible connection, copper braided belt flexible connection, etc., is a flexible connection conductive component with copper braided wire as the main body. It is mainly composed of high-purity copper braided wire, which is usually woven with multiple strands of fine copper wire to obtain good flexibility and a large conductive cross-sectional area. The two ends of the connection are generally fixed with copper terminals or copper bars through special processes (such as crimping, welding, etc.) to form an interface for installation and connection. The middle braided wire part is used as the main body of the flexible connection to achieve flexible conductive connection, which can adapt to different installation spaces and displacement changes during equipment operation under complex working conditions.

(I) Material selection
Select high-quality copper with a copper content of more than 99.9% as raw material. Copper has excellent electrical conductivity, thermal conductivity and ductility, and is very suitable for making flexible connection busbars. The diameter of the copper wire used for weaving is usually between 0.1 and 0.3 mm. The combination of multiple strands of copper wire can ensure sufficient conductivity and good flexibility of the braided wire.

(II) Weaving
Use professional weaving equipment to weave multiple strands of copper wire according to a specific weaving method. Common weaving methods include plain weaving and twill weaving. Plain weaving has a tight structure and a smooth appearance; twill weaving has better flexibility and tensile strength. The weaving density is generally between 80% and 95%. A higher weaving density can improve the overall performance of the Copper Braided Flexible Connectors, such as conductivity and mechanical strength.

(III) Connection end processing
Crimp: Place one end of the Flexible Braided Custom Connectors into a special copper terminal or copper busbar connection, and use professional crimping tools, such as hydraulic crimping pliers, to apply a certain amount of pressure to tightly combine the copper terminal or copper busbar with the braided wire. During the crimping process, the pressure and crimping time must be controlled to ensure a firm connection. The resistance value after crimping should meet the requirements of relevant standards and generally does not exceed the specified micro-ohm level.

Welding: For some occasions that require higher connection reliability, welding technology will be used. Common welding methods include argon arc welding. First, clean the welding part to remove impurities such as oil and oxide on the surface, and then weld the braided wire with the copper terminal or Braided Flexible Busbar under a protective gas (argon) environment using a suitable welding current and welding time. After welding, the weld should be full and smooth, without defects such as cold solder joints and pores, and the strength and conductivity of the welding part must meet the use requirements.

(IV) Post-processing
Clean the finished copper braided wire soft connection busbar to remove impurities such as flux and oil residue on the surface. Then, according to the use environment and customer needs, perform surface treatment, such as tin plating, silver plating, etc. Tin plating can improve the product's antioxidant and anti-corrosion properties, and is suitable for general industrial environments; silver plating can further reduce contact resistance and improve conductivity, and is often used in fields such as electronic equipment that require extremely high conductivity.

High conductivity: Since copper itself has good conductivity and the large conductive cross-sectional area formed by braiding multiple strands of copper wire, the Copper Braided Flexible Busbar performs well in conductivity and can meet the needs of large current transmission. Its DC resistivity is generally around 0.017Ω・mm²/m (20℃), which can ensure efficient and stable current transmission.

Excellent flexibility: The structure woven from multiple strands of fine copper wire gives the product extremely high flexibility, which can be freely bent and twisted within a certain range, and can easily adapt to vibration, displacement and other conditions during equipment operation, effectively avoiding line damage caused by rigid connection, and extending the service life of the connection parts.

Good heat dissipation: The high thermal conductivity of copper enables the Flexible Insulated Copper Busbars to quickly dissipate the heat generated while conducting current, which helps to maintain the normal operating temperature of the equipment and improve the stability and reliability of the equipment.

Strong seismic resistance: In a vibrating working environment, the Copper Braided Wire can absorb and buffer vibration energy, reduce the damage to the connection parts and equipment caused by vibration, and ensure the stability of power transmission.

Easy installation: Its soft and bendable characteristics make it easy to adjust the shape during installation to adapt to different installation space and angle requirements, reducing installation difficulty and improving installation efficiency.