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Flexible Copper Braided Connectors from China - Trusted Suppliers & Factory for Precision Equipment Solutions
Structure Composition
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.
Frequently Asked Questions
What base materials are used for the braided copper structure?
The base material consists of high-purity electrolytic copper wire (mainly T1/T2 red copper) that offers low-loss current transmission, high thermal conductivity, and stable connection temperatures. Optional plating materials include tin-plated copper, silver-plated copper, or specialized antioxidant coatings.
Can the dimensions and wire diameters be customized?
Yes. Xingma Copper can customize the square footage (Nominal CSA) and individual wire diameters ranging from 0.05mm to 0.15mm based on your project requirements. The braiding configuration (8 to 48 spindles) and cutting lengths can also be fully customized according to your drawings or specifications.
What are the primary benefits of using a braided structure design?
The braided design provides extreme flexibility (allowing tight bending radiuses of 5-10 times the wire diameter) and high resistance to repeated torsion. It is highly durable mechanically, outperforming standard flexible wires in tensile strength and dynamic bending cycles.
What functional enhancement layers can be applied?
To improve performance in harsh environments, optional layers can be added. These include PVC or silicone sleeves for insulation, metal shielding for electromagnetic interference (EMI) resistance, and high-temperature coatings rated to withstand temperatures from -40°C to +120°C.
In which industries are these braided copper conductors used?
They are widely utilized across multiple industries, including Power & Energy (transformers, busbars), Rail & Vehicles (pantographs, EV batteries), Industrial Automation (robotic joints), New Energy (PV, wind turbines), Marine & Offshore, and Smart Building Facilities.