Flat Woven Copper Cables
Yeshwant Wires is a prominent Flat Woven Copper Cables manufacturer in India, specializing in flexible, high-conductivity woven copper cables designed for earthing, bonding, and high-current transmission applications. These cables are made from multiple fine copper wires woven together in a flat, uniform pattern that ensures superior flexibility, excellent conductivity, and long-term durability.
Available in bare, tinned, or silver-plated finishes with custom widths and thicknesses, these cables deliver exceptional flexibility, low resistance, high current capacity, and corrosion resistance. They comply with IS 8130, IEC 60228, and ASTM B172 standards and are ideal for transformers, switchgear, power panels, grounding systems, and battery connections.
Description
Flat Woven Copper Cables are flexible conductors made by weaving multiple fine copper strands into a flat braid form. This structure offers excellent flexibility and is particularly suited for dynamic applications where vibration, movement, or mechanical stress is present. With a wide surface area and uniform current distribution, they minimize resistance and voltage drop while improving heat dissipation.
These cables are extensively used in power distribution, switchgear connections, earthing systems, transformers, battery interconnections, railways, and industrial automation where flexibility, conductivity, and compliance with electrical safety standards are paramount for operational excellence and reliable performance.
Key Features & Advantages
- High Conductivity: Manufactured from 99.99% pure electrolytic-grade copper.
- Excellent Flexibility: Ideal for movable electrical joints and vibrating installations.
- Corrosion Resistant: Available with bare, tinned, or silver plating.
- Low Resistance: Uniform weaving minimizes power loss and heat generation.
- High Current Carrying Capacity: Suitable for heavy-duty electrical connections.
- Custom Sizes: Manufactured in various widths, thicknesses, and cross-sections.
Technical Specifications
| Property | Specification | Significance |
|---|---|---|
| Conductor Material | High-Purity Electrolytic Copper (Cu-ETP), available Bare or Tinned (Tin-plated). | The high conductivity of copper ensures efficient current flow. Tinning is a standard option to provide superior corrosion and oxidation resistance, ensuring long-term low-resistance connections, especially in harsh environments. |
| Construction Type | Ultra-Fine Strands (e.g., 0.05mm to 0.25mm diameter) are woven into a dense, flat braid (like a ribbon). | This defining construction provides maximum flexibility in all directions and a large surface area for connecting to terminals. The woven structure is highly durable and resistant to vibration and flexing fatigue. |
| Cross-Sectional Area (CSA) | Standard sizes range from 0.75 mm² up to 400 mm² (or equivalent AWG/kcmil sizes). | The cross-section determines the current-carrying capacity (Ampacity). The flat shape offers a significantly larger surface area for heat dissipation compared to a round cable, which can lead to a higher effective current rating for a given CSA. |
| Dimensions | Defined by Nominal Width (e.g., 4 mm to 50 mm) and Nominal Thickness (typically very thin, e.g., 1 mm to 8 mm). | The low-profile, flat design allows for efficient use of space in crowded cabinets, switchgear, and terminals, making it ideal for creating flexible links between components. |
| Insulation/Sheath | Typically supplied Uninsulated (Bare) or with an extruded clear PVC/Silicone sleeve (when insulation is required). | The primary function is as a conductive, highly flexible link or shield, not a power delivery cable requiring full dielectric isolation. When used as a flexible busbar, a thin sleeve prevents accidental contact and corrosion. |
| Current Rating (Ampacity) | Significantly higher than an equivalent cross-section round cable, due to the large surface area for cooling. | This high rating makes them suitable for high-current applications such as connecting battery banks, electrolytic cells, and large power transformers. |
| Key Function | High-Flex Grounding Jumper, Flexible Electrical Bonding Strap, EMI/RFI Shielding, and Flexible Busbar Link. | Used in applications requiring a low-resistance, high-current path and continuous or frequent movement, such as robot arms, rail rolling stock, vibration isolation for large machinery, and main switchgear connections. |
| Relevant Standards | ASTM-B33, MIL-Spec AA59569, and various proprietary industry standards for dimensional and mechanical tolerance. | Compliance ensures the braid meets industry standards for material purity, dimensional consistency, and electrical resistivity, which is vital for safe and reliable grounding and power transfer. |
Applications
Flat Woven Copper Cables are widely used in power distribution, switchgear connections, earthing and grounding systems, transformers, battery interconnections, railways, automotive, and industrial automation. Their flexible structure and high conductivity ensure safe and efficient operation in installations where mechanical stress, vibration, and reliable current flow are essential.
Manufacturing & Quality Assurance
At Yeshwant Wires, every flat woven copper cable is produced using advanced braiding and weaving machines for precision and reliability. Cables undergo stringent testing for tensile strength, electrical resistance, conductivity, finish quality, and mechanical strength under ISO certified quality systems.
Why Choose Yeshwant Wires?
- Leading Flat Woven Copper Cables Manufacturer in India.
- High-purity copper with customizable width, thickness, and coating options.
- Flexible construction suitable for dynamic and high-stress applications.
- Competitive prices with timely delivery across India and international markets.
- Trusted supplier for power distribution and electrical systems.
Industries We Serve
We supply Flat Woven Copper Cables to diverse industries such as electrical, power generation, renewable energy, transportation, railways, automotive, and industrial automation. Our solutions are tailored for high performance, safety, reliability, and compliance with international electrical standards.
