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Flexible Copper Braided Connectors from China Factory - High-Conductivity Solutions by Reliable Suppliers
Structure Composition
Base Material
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.
Material 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.
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).
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
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 |
| 10 | 576 | 48*12*1/0.15 | 16/1.5 |
| 12 | 720 | 24*30*1/0.15 | 14/2 |
| 12 | 720 | 48*15*1/0.15 | 18/1.5 |
| 16 | 8160 | 24*340*1/0.05 | 16/2.2 |
| 16 | 960 | 24*50*1/0.15 | 16.2.2 |
| 16 | 960 | 48*20*1/0.15 | 22/1.8 |
| 20 | 1200 | 24*50*1/0.15 | 18/2.5 |
| 20 | 1200 | 48*25*1/0.15 | 25/2.0 |
| 25 | 12720 | 48*265*1/0.05 | 22/3.0 |
| 25 | 1440 | 48*30*1/0.15 | 28/2.2 |
| 25 | 1440 | 48*15*2/0.15 | 25/2.3 |
| 35 | 1920 | 48*20*2/0.15 | 26/3.5 |
| 35 | 17832 | 24*743*1/0.05 | 25/4.0 |
| 50 | 2880 | 48*30*2/0.15 | 30/3.5 |
| 50 | 2880 | 48*20*3/0.15 | 28/4.8 |
| 50 | 25440 | 48*265*2/0.05 | 25/5.0 |
| 100 | 5760 | 48*30*4/0.15 | 38/6.0 |
| 100 | 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.
Frequently Asked Questions
What materials are used in Xingma's braided copper structures?
We use high-purity electrolytic copper wire (mainly T1/T2 red copper) as the base material. For enhanced performance, we also offer options like tin-plated copper (for better soldering), silver-plated copper (for high-frequency conductivity and corrosion resistance), and specialized antioxidant coatings.
Can I customize the wire diameter and cross-sectional shape?
Yes, absolutely. We can customize the square footage, individual wire diameter (ranging from 0.05mm to 0.15mm), cross-sectional shape (round, flat, or custom), length, and the overall braiding configuration based on your drawings or specifications.
What are the main application fields for flexible copper braids?
They are widely used in Power & Energy (transformer leads, busbar transitions), Rail & Vehicles (EV battery modules, pantographs), Industrial Automation (robotic joints), New Energy (PV and wind turbine pitch systems), Marine equipment, and smart building facilities.
How flexible are these braided copper connectors?
Our braided structures feature extreme flexibility, enabling a tight bending radius of 5 to 10 times the wire diameter. They are highly resistant to repeated torsion and dynamic movements, making them perfect for confined spaces like robotic joints.
What kind of environmental protection options do you provide?
We offer optional functional enhancement layers including PVC or silicone sleeves for insulation, metal shielding for EMI resistance, and high-temperature coatings capable of withstanding temperatures from -40°C to +120°C.