Custom Flexible Rectangular Copper Busbar for High-Current Connections Manufacturer, Suppliers

This product is a high-performance flexible rectangular braided copper wire. Its core structure utilizes multiple high-purity annealed copper wires, precisely braided and rolled to form a rectangular cross-section. It retains the high current-carrying capacity and low impedance of solid busbars while offering the unique dynamic flexibility and mechanical fatigue resistance inherent to braided conductors. This enables stable conductivity during multi-directional bending and in vibrating environments. To ensure the product perfectly matches your requirements, please specify the following when requesting a quote: nominal cross-sectional area, number of braiding machine carriers, wire count per strand, and required wire diameter. Providing these details will allow us to deliver the optimal solution.

Product Description

Product Features
High Purity

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.

Robust Structure

Precision-braided on 8/12-carrier machines to form a uniform rectangular (flat wire) cross-section, eliminating localized stress concentration and preventing deformation.

Adaptability

Offers excellent flexibility, strong EMI shielding effectiveness, and reliable structural integrity. Adjustable braiding density meets diverse strength requirements.

Customization

Fully customizable: nominal cross-sectional area, strand diameter (0.05mm-0.15mm), cut length, and carrier count (8/12 options).

Application Fields
  • Electrical connections: Power equipment grounding, new energy battery interconnects.
  • Electromagnetic shielding: Communication and high-frequency equipment protection.
  • Grounding systems: Rail transit and industrial equipment safety grounding.
  • High-end electronics: Critical components for conduction and anti-interference in complex environments.
Structural Composition

High-Purity Copper Strands: Soft copper strands (0.05mm to 0.15mm diameter) with ≥99.9% purity form the conductive base.

Multi-Carrier Braided Structure: Strands are interlaced via 8 or 12-carrier braiding machines. The 8-carrier configuration suits standard precision, while 12-carrier provides enhanced density for heavy-duty industrial use.

Rectangular Cross-Section: Post-braiding shaping creates a profile that increases contact area by over 30% compared to round wires, simplifying installation and improving stability.

Product Specifications
Nominal CSA (mm²) Structure Approx. Weight (km/kg)
Total Wires Strands * Wires * Cores / Diameter
0.552808*35/0.055.33
0.653368*42/0.056.30
0.753848*48/0.057.27
0.904568*57/0.058.72
1.005128*64/0.059.69
1.507688*96/0.0514.53
2.0010248*128/0.0519.38
2.5012808*160/0.0524.22
3.0016808*210/0.0529.06
4.0020488*256/0.0538.75
5.0025608*320/0.0548.44
6.0030728*384/0.0558.13
8.0040808*510/0.0577.50
25.001284012*1070/0.05242.19
10.0012808*160/0.198.67
16.0020408*255/0.1157.87
25.0029608*370/0.1246.68

Customization is available for square areas with single wire diameters ranging from 0.05mm to 0.15mm. Braided wires are produced using 8-spindle or 12-spindle machines with lengths cut to specific requirements.

Frequently Asked Questions
What is the purity of the copper used in these braided wires?
We use high-purity soft copper strands with a purity level of ≥99.9%, ensuring maximum conductivity and minimal signal or power loss.
What is the advantage of a rectangular cross-section over round wire?
The rectangular profile increases the contact surface area by more than 30%, which allows for better mating with flat terminals and improved heat dissipation and stability.
Can I request custom lengths and wire diameters?
Yes, we offer flexible customization. You can specify the strand diameter (between 0.05mm and 0.15mm) and the precise cut lengths based on your technical drawings.
What are the different braiding carrier options?
We utilize 8-carrier and 12-carrier braiding machines. The 8-carrier is ideal for standard precision and compact electronics, while the 12-carrier offers higher density for heavy-duty industrial applications.
Are these braided wires suitable for high-frequency environments?
Yes, the precision-braided structure provides excellent EMI (Electromagnetic Interference) shielding, making them highly effective for communication and high-frequency equipment.

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