China Insulated Copper Flexible Connectors for New Energy Vehicles - Top Suppliers & Factory Direct Products
Insulated Copper Flexible Connector Features
- 🛡️ High insulation performance
- 🔄 Flexible displacement compensation
- ⚡ High current carrying capacity and low loss
- 🔧 Installation convenience
Technical Data for Insulated Copper Flexible Connector
| Product type | Laminated insulated copper busbar flexible connection | Braided insulated copper busbar flexible connection |
| Conductor parameters |
Conductor material: T2 oxygen-free copper; Specification 1: (15.5×0.8×2mm), cross-sectional area 24.8mm²; Specification 2: (20×1×5mm), cross-sectional area 100mm²; Specification 3: (40×1×8mm), cross-sectional area 320mm²; Specification 4: (50×1×10mm), cross-sectional area 500mm² |
Conductor material: T2 oxygen-free copper (copper content > 99.95%); The conventional diameter of the monofilament is 0.15mm, and 0.05–0.25mm is available as an option. Surface treatment: Bare copper / tin plating / nickel plating; Specification 1 (Small Size): Cross-sectional area 30mm²; Specification 2 (Medium Size): Cross-sectional area 150mm²; Specification 3 (Large Size): Cross-sectional area 500mm² |
| Insulation parameters |
Material: PVC / heat shrink tubing (EVA/PE); Dielectric strength > 20kV/mm; Flame retardant grade: UL94 V-0; Operating temperature: -40℃ to 125℃ |
Material: Silicone rubber / fluoroplastic; Dielectric strength > 23kV/mm; Flame retardant grade: UL94 V-0; Operating temperature: -45℃ to 200℃ |
| Current Capacity (A) |
Specification 1: 125A when △T=20K, 200A when △T=50K; Specification 2: 300A when △T=20K, 490A when △T=50K; Specification 3: 600A when △T=20K, 920A when △T=50K; Specification 4: 750A when △T=20K, 1300A when △T=50K |
Specification 1: 150–300A Specification 2: 600–1000A Specification 3: 1500–3000A |
| Main Application |
New energy vehicle battery packs, UPS systems, High and low voltage switch cabinets |
Rail transit traction converters, Industrial electric arc furnaces, Energy storage power stations |
| Core Advantage | The laminated structure reduces the skin effect, with less contact between the insulating layer and the conductor, high flexibility, and the ability to be folded and twisted. | It has strong seismic resistance, is suitable for equipment vibration and thermal expansion and contraction, and has better high-temperature resistance than laminated type. |
The Core Structure for Insulated Copper Flexible Connector
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1Conductive Core High-purity oxygen-free copper braided tape (or copper foil lamination) is adopted as the core conductive component. Both ends are solidified into solid copper terminals through cold pressing or brazing processes to ensure high current transmission capacity and connection reliability.
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2Insulating Protective Layer Insulating materials are coated on the surface of the conductive core. Common processes and materials are as follows:
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3Heat Shrink Tube Coating Polyolefin, fluoroplastic (PTFE, PVDF) or silicone rubber heat shrink tubes are selected. After heating, they are closely attached to the core body. The insulation layer thickness is 0.3–2.0mm, and it has the characteristics of flame retardancy, high-temperature resistance and acid and alkali corrosion resistance.
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4Dip Molding Process The core is immersed in epoxy resin or polyurethane insulating resin. After curing, a uniform insulating layer is formed, with a protection level up to IP67, making it suitable for damp and dusty environments.
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5Local Insulation Spraying Only the non-connection areas are sprayed with insulating paint, leaving the terminal parts exposed to meet the conductive connection requirements of specific scenarios.
Customization Options For Insulated Copper Flexible Connector:
The connector length, width, thickness, hole number and sizes, Cross Sectional Area, insulated materials — all can be customized as your request.
Package & Shipping for Copper Foil Flexible Busbar
