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Flexible Copper Busbar
A Flexible Braided Copper Busbar is an advanced electrical component made by braiding multiple fine copper strands into a flexible, yet highly conductive structure. Unlike rigid copper bars, this type of Flexible Copper Busbar offers superior adaptability and can bend or twist to fit complex layouts. This makes it ideal for installations in confined or dynamic environments such as electric vehicles, renewable energy systems, switchgear, and industrial machinery.
Compared to traditional solid Copper Busbars, Braided Copper Busbars provide better vibration resistance, improved thermal performance, and ease of installation, all while maintaining copper’s excellent conductivity.
The production process involves several precise steps:
Material Selection – High-purity, oxygen-free copper wires are selected for their excellent electrical and thermal conductivity.
Stranding & Braiding – The copper wires are drawn into fine strands and then woven in a specific braiding pattern to create flexibility and strength.
Forming & Shaping – The braided copper can be shaped into Custom Braided Copper Busbar forms to meet unique installation requirements.
Insulation & Coating – Optional insulation layers (for Insulated Flexible Copper Busbar) or surface plating (tin, nickel, silver) can be added for protection against oxidation, corrosion, and wear.
Testing & Quality Control – Each Flexible Braided Busbar undergoes electrical conductivity, current capacity, and mechanical durability testing to ensure compliance with international standards.
Compared with rigid copper bars and other flexible connectors, our busbars have unique advantages:
Superior Flexibility – Can bend, twist, and adapt to different layouts, unlike rigid copper bars.
High Conductivity – Copper ensures low resistance and efficient power transmission.
Vibration Resistance – The braided design absorbs mechanical stress, ideal for EVs and machinery.
Durability – Resistant to fatigue, wear, and thermal expansion.
Customization – Available as Custom Braided Copper Busbar, with various dimensions, insulation, or coatings.
Enhanced Safety – Optional Insulated Flexible Copper Busbar prevents short circuits and improves protection.
We provide different types of Flexible Copper Busbars to match diverse applications:
Flexible Braided Copper Busbar – Standard braided structure for flexibility and conductivity.
Laminated Flexible Copper Busbar – Layers of copper sheets laminated together for high current capacity.
Insulated Flexible Copper Busbar – With protective insulation for added safety in electrical systems.
Flexible Copper Connector – For easy integration between busbars and electrical equipment.
Flexible Copper Shunt – Used in current measurement and distribution systems.
Braided Copper Connector – Provides flexible, conductive connections in confined spaces.
| Parameter | Specification (Customizable) |
|---|---|
| Material | High-purity copper (≥ 99.9% Cu) |
| Construction | Braided strands or laminated sheets |
| Thickness | 2 mm – 20 mm |
| Width | 10 mm – 200 mm |
| Length | Custom length (up to 6 meters) |
| Current Capacity | Up to 2000 A (depending on size) |
| Surface Treatment | Bare, tinned, nickel-plated, silver-plated |
| Insulation Options | PVC, heat-shrink, epoxy coating |
| Operating Temperature | -50°C to +200°C |
| Standards | IEC, RoHS, ISO certified |
Flexible Copper Busbars are widely used across industries:
Power Distribution Systems – Switchgear, distribution boards, substations.
Renewable Energy – Solar inverters, wind turbine connections, battery storage.
Automotive & EVs – Battery pack connections, grounding, high-current distribution.
Industrial Machinery – Motors, generators, and control panels.
UPS & Telecom Systems – Reliable connections in continuous power systems.
Ensure correct sizing of the busbar according to current requirements.
Avoid excessive bending radius to maintain conductor integrity.
For Insulated Flexible Copper Busbar, check insulation regularly for wear.
Use protective coatings or plating in corrosive environments.
Perform routine inspections to detect overheating, vibration wear, or oxidation.
Compared with other suppliers, we provide:
Custom Solutions – We specialize in Custom Braided Copper Busbars tailored to your requirements.
Complete Range – From Flexible Braided Copper Busbar to Laminated Flexible Copper Busbar and Insulated Flexible Copper Busbar.
Certified Quality – ISO and RoHS compliance, meeting global standards.
Global B2B Supply – Large-scale production and export to support bulk procurement.
Competitive Pricing – Cost-effective solutions without compromising on quality.
Q1: What is a Flexible Braided Copper Busbar?
A Flexible Braided Copper Busbar is a conductor made of braided copper strands, providing flexibility and high conductivity for power distribution systems.
Q2: What are the advantages of Flexible Copper Busbars?
They offer excellent conductivity, flexibility, vibration resistance, and easy installation compared to rigid copper busbars.
Q3: Where are Flexible Braided Busbars commonly used?
They are used in power distribution, EV battery systems, renewable energy, UPS, and industrial equipment.
Q4: What’s the difference between Laminated and Braided Copper Busbars?
Laminated Flexible Copper Busbars have stacked copper sheets for higher current capacity, while Braided Copper Busbars offer superior flexibility.
Q5: Can I order Custom Braided Copper Busbars?
Yes, we provide fully customized busbars in terms of size, coating, insulation, and design to meet your specific needs.
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