Insulated Flexible Copper Connector for Control Systems - High-Quality China Suppliers and Factory Solutions
Detailed Explanation of Product Structure
Conductor Layer (Core)
It is precisely interwoven into a flat band structure by hundreds of high-purity T2 copper wires using herringbone or plain weave methods. Each strand contains 16 to 96 fine wires, with a single wire diameter of 0.05 to 0.25mm.
This structure makes the current distribution more uniform, reduces the skin effect and enhances the conductivity efficiency.
Insulating Protective Layer
- Inner Layer: High-performance polyester film or mica tape, providing basic electrical insulation.
- Middle Layer: Low smoke zero halogen TPE or XLPE, main insulating layer, temperature resistance 105–150℃, flame retardant grade UL94 V0.
- Outer Layer: Anti-wear sheath, available in transparent or colored options, enhancing mechanical protection and recognizability.
End Processing (Optional)
- Crimped Terminal: Copper nose, wiring lugs, convenient for bolt connection.
- Welding: Copper-aluminum transition welding and lap welding to form a firm connection.
Applications for Insulated Flexible Copper Connector
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New Energy Sector
Electric vehicles, energy storage systems, photovoltaic / wind energy.
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Industrial Automation
Electrical control systems, robots, precision equipment.
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Rail Transit & Special Equipment
Train traction systems, medical equipment, aerospace.
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Power Equipment Connection
Transformers, switchgear, generators.
Package & Shipping For Insulated Flexible Copper Connector
Frequently Asked Questions (FAQ)
Q
What materials are used for the conductor layer of the Insulated Flexible Copper Connector?
The conductor layer is made from hundreds of high-purity T2 copper wires, precisely interwoven into a flat band structure using herringbone or plain weave methods. Each strand contains 16 to 96 fine wires, with a single wire diameter ranging from 0.05 to 0.25mm, ensuring uniform current distribution and excellent conductivity.
Q
What is the temperature resistance rating of the insulating protective layer?
The middle insulating layer uses low smoke zero halogen TPE or XLPE material, which offers a temperature resistance of 105–150℃ and meets the UL94 V0 flame retardant grade standard, making it suitable for high-temperature and safety-critical environments.
Q
What end processing options are available for the connector?
Two main end processing options are available: Crimped Terminals (including copper nose and wiring lugs for easy bolt connections) and Welding (including copper-aluminum transition welding and lap welding for firm, reliable connections). These options can be customized based on your application requirements.
Q
Which industries are Insulated Flexible Copper Connectors suitable for?
These connectors are widely used across multiple industries, including the new energy sector (electric vehicles, energy storage systems, photovoltaic and wind energy), industrial automation (control systems, robots, precision equipment), rail transit and special equipment (train traction, medical devices, aerospace), and power equipment connections (transformers, switchgear, generators).
Q
What are the advantages of the multi-layer insulation structure?
The three-layer insulation design provides comprehensive protection: the inner polyester film or mica tape ensures basic electrical insulation, the middle TPE/XLPE layer handles high-temperature and flame resistance, and the outer anti-wear sheath adds mechanical protection. This layered structure significantly extends the service life of the connector in demanding environments.
Q
How does the woven structure of the copper conductor reduce the skin effect?
By interlacing hundreds of fine copper wires into a flat braided band, the conductor increases the effective surface area and ensures that current is distributed evenly across all strands. This minimizes the skin effect — the tendency of AC current to concentrate on the outer surface of a conductor — thereby improving overall conductivity efficiency and reducing energy loss.