Braided Flexible Connections

Product Overview

Product: Braided Flexible Connections

Material: High purity electrolytic copper Cu ETP/Cu DHP (≥ 99.9% Cu)

structure

Braided tape: flat/round, fine thread 0.10mm/standard thread 0.20mm (optional 0.3mm)

End: Crimson copper sleeve crimping, can be strengthened by brazing

Core advantages: good flexibility, excellent heat dissipation, dynamic stability and anti vibration, low contact resistance, long service life, easy installation

Design and Craftsmanship

Weaving structure

Flat/circular weaving options are available, with softer filaments and higher current carrying capacity for standard filaments.

End process

Copper sleeve crimping; Can be brazed to eliminate capillary water absorption and internal corrosion, reduce contact resistance and heat generation.

End expansion design

To prevent the braided wire from being pinched or sheared, and to withstand electric shock.

surface treatment

Bare copper, tin plating, silver plating, nickel plating, and gold plating are optional to enhance conductivity and corrosion resistance.

Typical applications

Power supply for industrial electric furnaces and electrolytic cells

Medium voltage equipment: switchgear, circuit breakers, frequency converters

Flexible connection between transformer and busbar

Flexible transition connections for power distribution systems and high current equipment

Product specification range

Section: 60~2000 mm ²

Weaving wire diameter: 0.1mm/0.2mm (0.3mm optional)

Basic cross-section: 60/75/100/150/200/250mm ²

Wall thickness of casing: 2mm

End standard length: 50/80/100/120mm

Customizable: angle bending, reinforced ultra flexible structure, drilling/milling end

Material Technical Parameters

1. Weave copper wire

Standard: NF EN 13602

Brand: Cu ETP

Conductivity: 100% IACS, resistivity 0.017241 Ω· mm ²/m

Tensile strength: ≥ 200MPa

2. End sleeve

Standard: EN 1057

Brand: Cu DHP, ≥ 99.9% Cu

Annealing treatment before crimping

3. Coating thickness

Tin plating: conventional 5 μ m/harsh environment 15 μ m

Silver plating: conventional 5 μ m/harsh environment 10 μ m

Current carrying capacity (AMPACITY)

Temperature limit

Bare copper/red copper: up to 85 ° C

Tin plated copper: up to 105 ° C

Maximum continuous current corresponding to ambient temperature

The document provides Imax values for 60-2000mm ² in an environment of 25/35/45 ° C, with larger cross-sections resulting in higher current carrying capacity; The current carrying capacity of tin plated copper with the same cross-section is higher than that of bare copper.

Example (partial):

100mm ²: 25 ° C bare copper 396A/tin plated 440A

400mm ²: 25 ° C bare copper 632A/tin plated 701A

1000mm ²: 25 ° C bare copper 1390A/tin plated 1542A

2000mm ²: 25 ° C bare copper 4193A/tin plated 4653A

Corresponding Table of Cross Section and End Size

Fixed combination of cross-section and end width, weaving combination:

60~250mm ²: single weave

300~500mm ²: Double woven

600~2000mm ²: Multiple weaving combinations

Example

300mm² = 2×150mm²

1000mm² = 4×250mm²

2000mm² = 8×250mm²

Installation Implementation Specification

1. Layout suggestions

Priority vertical installation

When used in parallel, the spacing should be greater than or equal to the connection thickness

2. Parallel scaling factor

Multiple parallel connections need to be multiplied by a reduction factor:

2 pieces: 1.8

3 pieces: 2.5

4 pieces: 3.2

5 pieces: 3.9

6 pieces: 4.4

8 pieces: 5.5

10 pieces: 6.5

3. End drilling specifications

Divided into I/II/III hole positions according to cross-section, with a standard aperture of 10-18mm, and customizable hole positions in A/B/C/D coordinates.

Order Model Identification Rules

Format: CS-TP – Section – Coating – Total Length

CS: Flexible Connection

TP: Flat Braid Flat Braid

TR: Sound Braid Circular Weaving

CRE: Tin plating

CRN: Bare Copper/Red Copper

Example: CS-TP-1000MM-CRE-LT500

Flat weave, 1000mm ², tin plated, total length 500mm

Summary of Core Interest Points

Low contact resistance+low heat generation: optimization of brazing process

Long lifespan: corrosion resistance, wire end shear resistance, electric power resistance

High flexibility: easy to install, compensating for displacement and vibration

Strong customization: section, length, angle, hole position, and coating can all be customized

Clear current carrying capacity: Full specification temperature current carrying meter can be directly selected