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China Flexible Rectangular Copper Busbar for High-Current Connections - Reliable Suppliers and Factory Solutions
Product Features
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⚡High Purity & Conductivity Utilizes 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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🔩Precise & Robust Structure Precision-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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🛡️Balanced Performance & Adaptability Offers 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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🔧Flexible Customization Fully 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
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Electromagnetic shielding — communication & high-frequency equipment
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Grounding systems — rail transit, industrial equipment safety grounding
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High-end electronics requiring anti-interference protection
It serves as a critical component for both conduction and shielding in complex environments.
Structural Composition
- 🟠 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.
- 🟠 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.
- 🟠 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 × Wires × 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 |
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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.
Frequently Asked Questions
What copper purity is used in these rectangular braided wires?
The rectangular braided wires use soft copper strands with a purity of ≥99.9%. This high purity ensures excellent electrical conductivity, low resistance, minimal transmission loss, and superior current-carrying capacity.
What strand diameters are available for customization?
Individual wire (strand) diameters range from 0.05mm to 0.15mm. The nominal cross-sectional area, carrier count (8 or 12 spindles), and cut length can all be customized based on customer drawings or specifications.
What is the difference between 8-carrier and 12-carrier braiding configurations?
The 8-carrier configuration is suited for standard precision applications such as compact electronics, while the 12-carrier option provides enhanced density and greater mechanical strength, making it ideal for heavy-duty industrial use.
Why is a rectangular cross-section preferred over a round wire design?
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 simplifies installation, improves long-term stability, and ensures even stress distribution to prevent deformation or broken strands.
What industries and applications are these braided wires suitable for?
These wires are widely used in electrical connections (power equipment grounding, new energy battery interconnects), electromagnetic shielding (communication and high-frequency equipment), grounding systems (rail transit and industrial safety), and high-end electronics requiring anti-interference protection.
Can the cutting length be customized to specific requirements?
Yes. Cutting lengths are fully customizable based on customer-provided drawings or specifications. Xingma Copper Industry supports flexible production to meet diverse project requirements across different industries.