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China Flexible Rectangular Copper Busbar Factory | High-Current Connections Suppliers with Low Impedance
Product Features
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⚡1. High Purity & ConductivityUtilizes soft copper strands with ≥99.9% purity to maintain inherent high conductivity. This ensures low resistance, minimal transmission loss, and exceptional current-carrying capacity.
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🔩2. Precise & Robust StructurePrecision-braided on 8/12-carrier machines to form a uniform rectangular (flat wire) cross-section. This design ensures even stress distribution, eliminating the localized stress concentration typical of round wires, thereby preventing deformation or broken strands during long-term use.
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🛡️3. Balanced Performance & AdaptabilityOffers excellent flexibility (resistant to breakage under repeated bending), strong EMI shielding effectiveness, and reliable structural integrity. The adjustable braiding density allows customization to meet diverse strength and application requirements.
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🔧4. Flexible CustomizationFully customizable based on key parameters: nominal cross-sectional area, strand diameter (0.05mm–0.15mm), cut length (per drawing/customer specs), and carrier count (8/12 options), ensuring a perfect fit for specific application needs.
Application Fields
This product is extensively used in:
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Electrical Connections
Power equipment grounding, new energy battery interconnects
Power equipment grounding, new energy battery interconnects
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Electromagnetic Shielding
Communication & high-frequency equipment
Communication & high-frequency equipment
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Grounding Systems
Rail transit, industrial equipment safety grounding
Rail transit, industrial equipment safety grounding
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High-End Electronics
Applications requiring anti-interference protection
Applications requiring anti-interference protection
It serves as a critical component for both conduction and shielding in complex environments.
Structural Composition
1
High-Purity Copper Strands
Soft copper strands with diameters from 0.05mm to 0.15mm and ≥99.9% purity form the conductive and structural base.
2
Multi-Carrier Braided Structure
Strands are interlaced via 8 or 12-carrier braiding machines. The 8-carrier configuration suits standard precision applications (e.g., compact electronics), while the 12-carrier option provides enhanced density and strength for heavy-duty industrial use. Uniform tension control prevents loosening or breakage.
3
Rectangular Cross-Section
Post-braiding shaping creates a uniform rectangular profile. Compared to round wires, this increases contact area by over 30% for better mating with flat terminals/enclosures, simplifies installation, and improves long-term stability through optimized stress dispersion.
Product Specifications
| Nominal CSA (mm²) | Structure | Rough Translation (km/kg) | |
|---|---|---|---|
| Total Number of Wires | Number of Strands * Number of Wires * Number of Cores / Nominal Diameter of Individual Wire | ||
| 0.55 | 280 | 8*35/0.05 | 5.33 |
| 0.65 | 336 | 8*42/0.05 | 6.30 |
| 0.75 | 384 | 8*48/0.05 | 7.27 |
| 0.90 | 456 | 8*57/0.05 | 8.72 |
| 1.00 | 512 | 8*64/0.05 | 9.69 |
| 1.50 | 768 | 8*96/0.05 | 14.53 |
| 2.00 | 1024 | 8*128/0.05 | 19.38 |
| 2.50 | 1280 | 8*160/0.05 | 24.22 |
| 3.00 | 1680 | 8*210/0.05 | 29.06 |
| 3.50 | 1784 | 8*223/0.05 | 33.91 |
| 4.00 | 2048 | 8*256/0.05 | 38.75 |
| 4.50 | 2296 | 8*287/0.05 | 43.59 |
| 5.00 | 2560 | 8*320/0.05 | 48.44 |
| 5.50 | 2800 | 8*350/0.05 | 53.28 |
| 6.00 | 3072 | 8*384/0.05 | 58.13 |
| 8.00 | 4080 | 8*510/0.05 | 77.50 |
| 25.00 | 12840 | 12*1070/0.05 | 242.19 |
| 10.00 | 1280 | 8*160/0.1 | 98.67 |
| 12.00 | 1536 | 8*192/0.1 | 118.40 |
| 16.00 | 2040 | 8*255/0.1 | 157.87 |
| 25.00 | 2960 | 8*370/0.1 | 246.68 |
ℹ️ Xingma Copper Industry can customize the square area according to customer requirements, with single wire diameters ranging from 0.05mm to 0.15mm. Rectangular braided wires are produced using 8-spindle or 12-spindle braiding machines. Cutting lengths are based on drawings or as specified by the customer.
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Frequently Asked Questions
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What copper purity is used in the rectangular braided wire, and why does it matter?
The rectangular braided wire uses soft copper strands with a purity of ≥99.9%. This high purity level ensures excellent electrical conductivity, low resistance, minimal signal/power transmission loss, and superior current-carrying capacity — all critical for reliable performance in power and electronic applications.
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What is the difference between 8-carrier and 12-carrier braiding configurations?
The 8-carrier configuration is ideal for standard precision applications such as compact electronics, offering a well-balanced combination of flexibility and conductivity. The 12-carrier configuration provides increased braiding density and greater mechanical strength, making it more suitable for heavy-duty industrial applications that demand higher durability and load capacity.
Q
What are the available strand diameter options, and can the cross-sectional area be customized?
Individual strand diameters range from 0.05mm to 0.15mm. The nominal cross-sectional area is fully customizable based on customer requirements, with available standard sizes ranging from 0.55mm² up to 25.00mm² and beyond. Custom specifications are welcomed to meet specific application needs.
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Why is a rectangular cross-section preferred over a round wire for certain applications?
The rectangular cross-section increases the contact area by over 30% compared to round wires, enabling better mating with flat terminals and enclosures. It also distributes mechanical stress more evenly, reducing the risk of deformation or strand breakage during long-term use, and simplifies installation in space-constrained environments.
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What industries and applications are rectangular braided copper wires commonly used in?
These wires are widely used across multiple industries, including power equipment grounding, new energy vehicle battery interconnects, EMI/electromagnetic shielding for communication and high-frequency equipment, safety grounding in rail transit systems, and anti-interference protection in high-end consumer and industrial electronics.
Q
Can the cutting length be customized, and what information is needed to place a custom order?
Yes, cutting lengths can be fully customized based on customer-provided drawings or written specifications. To place a custom order, customers should provide the required nominal cross-sectional area, preferred strand diameter, desired cut length, and carrier count (8 or 12). Xingma Copper Industry will then produce the product to exact specifications.