Flexible Copper Connector Basics and Applications
2025-08-08
Introduction to Flexible Copper Connectors
Flexible copper connectors are essential components in electrical systems, providing reliable conductivity while accommodating movement and vibration. At Dongjue, we specialize in manufacturing high-performance flexible copper connectors that meet international standards for power distribution, industrial equipment, and renewable energy applications.
Key Features of Dongjue Flexible Copper Connectors
Material Specifications
| Component | Material Grade | Conductivity | Temperature Range |
|---|---|---|---|
| Conductor | Oxygen-free copper (C10100) | ≥101% IACS | -40°C to 150°C |
| Insulation | Silicone rubber | N/A | -60°C to 200°C |
| Terminal | Electrolytic copper (C11000) | ≥98% IACS | -40°C to 130°C |
Product Line Overview
| Model | Current Rating | Voltage Class | Bend Radius | Certifications |
|---|---|---|---|---|
| DJ-FCC100 | 200A | 1kV | 5xOD | UL, CE |
| DJ-FCC200 | 500A | 3kV | 8xOD | IEC, RoHS |
| DJ-FCC300 | 1200A | 10kV | 10xOD | ANSI, IEEE |
Technical Advantages
Performance Characteristics
✔ Ultra-flexible design (5000+ bend cycles)
✔ Low impedance (<0.1mΩ/ft)
✔ Vibration resistance (up to 20G acceleration)
✔ Corrosion protection (tin or silver plating options)
Quality Assurance
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100% conductivity testing
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X-ray inspection of crimp connections
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Salt spray testing (500+ hours)
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Flame retardant certification (UL94 V-0)
Applications of Flexible Copper Connectors
Industrial Applications
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Transformer busbar connections
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Generator lead terminations
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Switchgear internal wiring
Renewable Energy
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Solar farm combiner boxes
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Wind turbine slip rings
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Battery energy storage systems
Transportation
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Railway overhead lines
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EV charging stations
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Marine power distribution
Installation Best Practices
Connection Methods
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Crimping (hydraulic or mechanical)
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Brazing (for high-temperature applications)
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Bolting (with proper torque values)
Maintenance Guidelines
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Annual inspection for oxidation
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Torque verification every 2 years
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Infrared scanning for hot spots
FAQ: Flexible Copper Connector Basics
Q: How do I select the proper size flexible copper connector for my application?
A: Consider these key factors:
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Current load: Calculate maximum continuous current (add 25% safety margin)
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Voltage level: Choose insulation rating above system voltage
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Movement requirements: Determine minimum bend radius needed
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Environment: Select appropriate plating/coating
Dongjue provides free engineering support for proper connector selection based on your specific parameters.
Why Choose Dongjue Flexible Copper Connectors?
✔ Precision laser-cut copper strips
✔ Custom configurations available
✔ ISO 9001 certified production
✔ 15-year performance guarantee
✔ Just-in-time delivery options
Get Your Custom Connector Solution
For technical specifications or application consulting:
📧 Email: [email protected]
With 20+ years in electrical component manufacturing, I personally guarantee Dongjue flexible copper connectors deliver unmatched reliability in the most demanding environments. Contact our engineering team today!
— Michael Zhang, Technical Director
Dongjue Electrical Components Co., Ltd.