Insulated Copper Flexible Connectors for New Energy Vehicles | China Suppliers & Factory
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): Cross-sectional area 30mm²; Specification 2 (Medium): Cross-sectional area 150mm²; Specification 3 (Large): 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) |
Spec 1: 125A (△T=20K), 200A (△T=50K); Spec 2: 300A (△T=20K), 490A (△T=50K); Spec 3: 600A (△T=20K), 920A (△T=50K); Spec 4: 750A (△T=20K), 1300A (△T=50K) |
Spec 1: 150–300A Spec 2: 600–1000A Spec 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. -
2Insulating Protective Layer
Insulating materials are coated on the surface of the conductive core. Common processes and materials are as follows: -
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. -
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. -
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 per your request.
Package & Shipping for Copper Foil Flexible Busbar
Frequently Asked Questions
What is the difference between laminated and braided insulated copper flexible connectors?
Laminated connectors use stacked copper foil layers, reducing the skin effect and offering high flexibility for folding and twisting — ideal for battery packs and switch cabinets. Braided connectors use woven copper strands, providing superior seismic resistance and high-temperature tolerance, making them suitable for rail transit, arc furnaces, and energy storage applications.
What insulation materials are available for the copper flexible connector?
Multiple insulation materials are available depending on your application: PVC, heat shrink tubing (EVA/PE) for laminated types; and silicone rubber or fluoroplastic for braided types. All materials meet UL94 V-0 flame retardant standards with dielectric strength exceeding 20kV/mm.
Can the insulated copper flexible connector be customized?
Yes. All key parameters can be customized, including connector length, width, thickness, hole number and size, cross-sectional area, and insulation material type. Please provide your technical requirements or drawings for a tailored solution.
What current capacity can the insulated copper flexible connector support?
Laminated types support from 125A up to 1300A depending on the specification and temperature rise (△T). Braided types support from 150A up to 3000A across three size specifications. Please refer to the technical data table above for detailed current ratings.
What surface treatments are available for the copper conductor?
For braided copper flexible connectors, three surface treatment options are available: bare copper, tin plating, and nickel plating. Tin plating improves corrosion resistance and solderability, while nickel plating offers superior oxidation resistance at higher temperatures.
What is the operating temperature range for insulated copper flexible connectors?
Laminated insulated connectors operate in a temperature range of -40℃ to 125℃, suitable for most indoor power and EV applications. Braided insulated connectors with silicone rubber or fluoroplastic insulation can withstand -45℃ to 200℃, making them ideal for high-temperature industrial environments.