Flexible Copper Braided Connectors for Precision Equipment
Flexible copper braided wire connectors use high-purity T1/T2 red copper (≥99.9% purity) as the conductor, manufactured through precision multi-strand twisting and braiding. Their unique flexible interwoven structure maintains exceptional electrical conductivity while delivering superior bending, twisting, and stretching adaptability. Designed specifically for dynamic, space-constrained, or vibration-prone electrical connections, these connectors replace rigid components with an optimal flexible solution that ensures reliable performance in demanding environments.
Base: High-purity electrolytic copper wire (mainly T1/T2 red copper) with high conductivity (resistivity ≤0.0175 Ω·mm²/m), thermal conductivity, and oxidation resistance for low-loss current transmission and stable connection temperature.
Options: Tin-plated copper (better soldering), silver-plated copper (enhanced high-frequency conductivity & corrosion resistance), or antioxidant coatings for special needs.
1. Braided Structure Design
Core: Hundreds to thousands of fine copper wires (diameter 0.05–0.3 mm) twisted into a dense, uniform bundle with specific lay direction (left/right).
Design: Precision-braided by machines (8/12/24/32/48 spindles) into mesh, tube, or custom shapes (e.g., flat/oval). Adjust density and strand count to balance flexibility with required tensile strength and deformation resistance.
2. Functional Enhancement Layers (Optional)
Surface: Bare copper (standard), tin-plated (anti-oxidation + soldering), or silver-plated (low-resistance + corrosion resistance).
Protection: PVC/silicone sleeves (insulation), metal shielding (EMI resistance), or high-temperature coating (-40°C to +120°C).
Application Fields
Power & Energy: Transformer flexible leads, dynamic connections for high/low voltage cabinets, soft busbar transitions, flexible conductive paths for welding machines/electrolysis equipment
Rail & Vehicles: Pantograph flexible connections, inter-car power/signal harnesses, dynamic conductive components for EV battery modules
Industrial Automation & Robotics: Conductive circuits for robotic joints, flexible motor connections, flexible sensor signal cables
New Energy: Flexible PV combiner connections, dynamic wind turbine pitch system conductors, flexible energy storage transitions
Marine & Offshore: Vibration-resistant electrical connections for engine rooms, corrosion-resistant conductive paths for marine equipment
Building & Smart Facilities: Sliding contact systems, flexible lighting power lines, concealed building conductive structures
Key Features
Extreme Flexibility: Braided structure enables tight bending (radius 5–10× wire diameter) and repeated torsion resistance, ideal for confined spaces, complex paths, or dynamic movement (e.g., robot joints, internal wiring of mobile devices).
High Conductivity: Copper core delivers near-solid-copper conductivity, ensuring stable transmission of high currents (up to thousands of amps, based on cross-section) or weak signals with low heat generation and minimal energy loss.
Mechanical Durability: Outperforms standard flexible wires in tensile strength and crush resistance, resists loosening or breaking during extended use, and supports high-cycle dynamic bending (tested for millions of bends).
Customizable Design: Precision-tailored to customer specs including conductor cross-section (mm²), strand diameter (0.05–0.3 mm), braiding strand count, length (custom-cut or blueprint-defined), cross-sectional shape (round/flat/custom), and surface treatment combinations.
Environmental Adaptability: Configurable protective layers enable operation in extreme conditions including high/low temperatures, humidity, salt spray, oil contamination, and EMI interference, suitable for industrial, outdoor, or specialized environments.
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
2.5
144
24*6*1/0.15
6/1
4
240
24*10*1/0.15
6/1.3
8
480
48*10*1/0.15
13/1.5
10
576
24*24*1/0.15
12.5/2
576
48*12*1/0.15
16/1.5
12
720
24*30*1/0.15
14/2
720
48*15*1/0.15
18/1.5
16
8160
24*340*1/0.05
16/2.2
960
24*50*1/0.15
16.2.2
960
48*20*1/0.15
22/1.8
20
1200
24*50*1/0.15
18/2.5
1200
48*25*1/0.15
25/2.0
25
12720
48*265*1/0.05
22/3.0
1440
48*30*1/0.15
28/2.2
1440
48*15*2/0.15
25/2.3
35
1920
48*20*2/0.15
26/3.5
17832
24*743*1/0.05
25/4.0
50
2880
48*30*2/0.15
30/3.5
2880
48*20*3/0.15
28/4.8
25440
48*265*2/0.05
25/5.0
100
5760
48*30*4/0.15
38/6.0
50880
48*530*2/0.05
32/6.0
Xingma Copper can customize the square footage and individual wire diameter (0.05mm – 0.15mm) according to customer requirements. Braiding is performed on braiding machines (8-spindle / 12-spindle / 24-spindle / 32-spindle / 48-spindle), with cutting lengths based on drawings or customer specifications.
