Flat Braided Copper Flexible Connectors
Yeshwant Wires is a renowned Flat Braided Copper Flexible Connectors manufacturer in India, offering premium-quality, high-conductivity connectors designed for superior flexibility and electrical performance. Our connectors are manufactured using multiple strands of fine electrolytic copper wires, tightly woven into a flat braid that provides excellent current-carrying capacity, mechanical strength, and vibration absorption.
Engineered for demanding industrial and electrical applications, these connectors deliver exceptional conductivity, flexibility, corrosion resistance, and durability. They comply with IS, IEC, and ASTM standards and are ideal for switchgear, transformers, busbars, and equipment experiencing vibration, thermal expansion, or relative movement.
Description
Flat Braided Copper Flexible Connectors are specialized components designed to provide flexible electrical connections between busbars, switchgear, transformers, and other current-carrying equipment. The flat braided structure increases surface area and flexibility while minimizing resistance and heat generation, ensuring efficient current transfer.
These connectors are extensively used in vibration-prone and high-current environments such as power distribution systems, automotive applications, and industrial machinery. They are ideal for switchgear, control panels, transformers, battery banks, welding equipment, solar energy systems, and railway electrical systems where reliable, low-resistance connections are essential.
Key Features & Advantages
- Excellent Conductivity: Made from 99.99% pure electrolytic copper for high current efficiency.
- Enhanced Flexibility: Flat braided design absorbs vibration and movement effectively.
- Corrosion Resistant: Optional tin or silver plating for long-term oxidation protection.
- Low Voltage Drop: Ensures consistent and efficient electrical performance.
- Custom Lengths & Terminals: Manufactured as per customer drawings and specifications.
- High Mechanical Strength: Ensures stable performance under electrical load and vibration.
- Maintenance-Free Operation: Reliable performance even under continuous duty conditions.
Technical Specifications
| Property | Specification | Significance |
|---|---|---|
| Conductor Material | High-Conductivity Electrolytic Copper (Bare or Tinned) | Copper ensures maximum current transfer. Tinned copper is often used in outdoor or corrosive environments for added protection. |
| Voltage Grade | Low to Medium Voltage (Application Dependent) | The voltage rating is often determined by the insulation (if present) or the clearances in the switchgear/busbar assembly they connect, commonly used up to 1 kV or higher for equipment bonding. |
| Operating Temperature | -40°C to +150°C (Tinning/Insulation Dependent) | The high temperature rating reflects the copper material and the robust termination methods, allowing them to handle the heat generated by high current flow. |
| Construction | Highly Flexible Flat Braid (Woven) | Defining Feature. The woven flat braid construction provides superior flexibility and resistance to metal fatigue, allowing the connector to withstand continuous vibration and movement. |
| Termination Ends | Solid Copper Lugs or Ferrules (Pressed/Welded) | The ends are typically solid copper or a compressed ferrule, which are cold-pressed or fusion-welded to the braid to ensure a low-resistance, gas-tight joint for reliable current transfer. |
| Insulation/Sleeve | Uninsulated (Bare) or PVC/Silicone Sleeve (Optional) | Most are uninsulated for maximum heat dissipation (air cooling). Insulation is added only when necessary for safety or environmental protection. |
| Key Function | Compensating for Vibration, Thermal Expansion, and Misalignment | Used extensively in switchgear, transformers, generators, and battery banks to prevent mechanical stress from damaging rigid busbars or terminals. |
Applications
Flat Braided Copper Flexible Connectors are used in a wide range of applications where reliable, low-resistance, and flexible electrical connections are essential:
- Switchgear and Control Panels
- Transformers and Busbar Connections
- Battery Banks and UPS Systems
- Welding Equipment and Generators
- Solar Energy Systems
- Automotive and Railway Electrical Systems
Manufacturing & Quality Assurance
At Yeshwant Wires, every flat braided copper connector is manufactured using precision braiding machines and automated crimping systems for reliability and performance. Connectors undergo rigorous testing for electrical conductivity, mechanical strength, flexibility, and coating thickness under ISO certified quality systems.
Why Choose Yeshwant Wires?
- Leading Flat Braided Copper Flexible Connectors Manufacturer in India.
- High-conductivity connectors designed for industrial and power applications.
- Custom sizes, terminal types, and finishes available on request.
- State-of-the-art manufacturing and testing facilities.
- Competitive pricing, timely delivery, and global export support.
Industries We Serve
We supply Flat Braided Copper Flexible Connectors to diverse industries such as power generation, automotive, electrical, renewable energy, marine, switchgear, and railway industries. Our solutions are tailored for high performance, precision, durability, and superior conductivity in mission-critical applications.
