Round Copper Braids
Yeshwant Wires is a leading Round Copper Braids manufacturer in India, providing high-quality, flexible, and durable copper braids used for earthing, bonding, electrical connections, and grounding applications. Our round copper braids are made from multiple fine strands of 99.99% pure electrolytic copper braided into a circular form, ensuring superior conductivity, flexibility, and mechanical strength.
Available in bare, tinned, or silver-plated finishes with custom diameters and strand counts, these braids deliver exceptional flexibility, high current capacity, corrosion resistance, and durability. They comply with IS 8130, IEC 60228, and ASTM B172 standards and are ideal for power systems, earthing, welding, busbar connections, and industrial machinery.
Description
Round Copper Braids are circular conductors made by interweaving multiple fine copper wires into a flexible rope-like structure. This design provides exceptional flexibility, high current-carrying capacity, and mechanical strength, making them ideal for dynamic electrical connections. The braids are designed to carry high currents efficiently while absorbing vibrations and thermal expansion in power distribution and industrial applications.
These braids are extensively used in power systems, earthing and grounding systems, welding equipment, busbar connections, transformers, battery banks, and renewable energy systems where reliable and durable electrical conductivity is paramount for operational excellence and safety in both industrial and power distribution applications.
Key Features & Advantages
- High Electrical Conductivity: Made from 99.99% electrolytic copper for efficient power transfer.
- Excellent Flexibility: Ideal for vibrating or movable electrical joints and dynamic applications.
- Corrosion Resistance: Available in bare, tinned, or silver-plated finishes for enhanced durability.
- Durable & Long-lasting: Withstands repeated bending and mechanical stress without degradation.
- High Current Capacity: Suitable for heavy-duty power applications and high-current transmission.
- Custom Sizes: Available in various diameters and strand counts per requirement.
Technical Specifications
| Property | Specification | Significance |
|---|---|---|
| Conductor Material | High-Purity Electrolytic Copper (Cu-ETP), typically available Bare or Tinned. | Copper provides high electrical conductivity. Tinning the copper strands significantly improves corrosion resistance and extends the service life, especially in humid or chemically aggressive environments. |
| Construction Type | Ultra-Fine Strands (e.g., 0.05 mm to 0.3 mm diameter) woven concentrically around a central axis to form a flexible tubular braid. | This construction offers the highest degree of omni-directional flexibility and excellent fatigue resistance, making it ideal for continuous, dynamic movement. |
| Cross-Sectional Area (CSA) | Wide range of sizes from very small (e.g., 1 mm²) up to large current carriers (e.g., 200 mm²). | The CSA dictates the current-carrying capacity. For a given CSA, round braids often have a lower Ampacity than flat braids due to less surface area for heat dissipation. |
| Flexibility Class | Generally meets or exceeds the requirements for IEC 60228 Class 5 or Class 6 conductors due to the fine strands and braided structure. | The high flexibility class confirms suitability for applications involving frequent bending, twisting, or vibration. |
| Insulation/Sheath | Typically supplied Uninsulated (Bare). Insulated versions often use PVC, Silicone, or Rubber compounds for dielectric protection. | Uninsulated braids are standard for grounding, shielding, and bonding. Insulation is added only when the braid carries voltage or requires protection from short circuits or abrasion. |
| Key Function | High-Flex Grounding Jumper, Electrical Bonding Strap, EMI/RFI Shielding Conduit, and Flexible Power Lead. | Primarily used to establish a reliable, low-impedance electrical connection across a moving or vibrating joint, or to provide an effective shield around insulated wires. |
| Applications | Automotive (battery and engine grounds), Rail (pantograph leads), Switchgear (flexible connections), and Cable Shielding (coaxial and high-frequency cables). | Their tubular shape and flexibility make them excellent for routing in tight spaces and wrapping around other cable bundles for shielding. |
| Termination Method | Often terminated by crimping or welding a seamless copper lug onto the braid ends to ensure a reliable connection point. | Proper termination is crucial for minimizing resistance and preventing fraying, ensuring the component retains its specified Ampacity. |
Applications
Round Copper Braids are widely used in earthing and grounding systems, busbars and switchgear connections, welding equipment, generators, transformers, industrial machinery, battery banks, renewable energy systems, automotive, and railway electrical systems. 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 round copper braid is produced using advanced braiding machines that ensure uniform strand distribution, consistent diameter, and superior flexibility. Braids undergo stringent testing for tensile strength, electrical conductivity, surface finish quality, and mechanical strength under ISO certified quality systems.
Why Choose Yeshwant Wires?
- Leading Round Copper Braids Manufacturer in India.
- High-purity copper with customizable diameter, strand count, and finish options.
- ISO-certified manufacturing with modern braiding and testing equipment.
- Competitive prices with timely delivery across India and international markets.
- Trusted supplier for power, electrical, renewable energy, and industrial sectors.
Industries We Serve
We supply Round Copper Braids to diverse industries such as electrical, power generation, renewable energy, automotive, railway, heavy equipment manufacturing, and industrial automation. Our solutions are tailored for high performance, safety, reliability, and compliance with international electrical standards.
