Highly flexible electricity
Highly flexible electrical connections are indispensable in modern electrical engineering and are used in many markets:
- Electromobility: As flexible battery connections in electric vehicles.
- Energy technology: As flexible electrical connectors in generators or transformers for effective use of installation space.
- Industrial applications: For transmitting high currents in welding and electrolysis systems.
- Railway technology: As grounding components in trains.
- Renewable energies: For power transmission in confined spaces in wind power and solar plants.
- Switchgear construction: As flexible power transmission components between switches and circuit breakers.
Copper braiding for three-dimensional movements
The subtle difference
The three most common highly flexible busbars are Braided Flexible Busbars, Ultraflexx® and Earth Braids. Although they are all made of individual wires, there are significant differences in material, cross-sections, connections, insulation and therefore areas of application.
The differences between our Braided Flexible Busbars and Earth Braids lie mainly in their dimensions, cross-sections, connections, and functions. While Braided Flexible Busbars are designed for highly flexible power transmission applications, Earth Braids are mainly used for grounding and EMC purposes.
Ultraflexx® are specialized for power transmission applications where maximum flexibility and insulation reliability are essential.
Advantages of highly flexible busbars
- Maximum flexibility: Whether in confined spaces or in dynamic applications, highly flexible busbars adapt to any direction of movement.
- High current carrying capacity: Copper has very low electrical resistance, which means that little energy is lost during current flow.
- Good heat dissipation: Flat braids has a large surface area in relation to its volume. This large surface area allows heat to be quickly dissipated into the environment.
- Long service life: High-quality materials and manufacturing standards ensure long and reliable use.
Copper braiding in comparison
| Braided Flexible Busbars | Ultraflexx® | Earth Braids | |
| Material | Machine-braided flat and round strands consist of thin individual wires made of Cu-ETP1, tin-plated Cu-ETP1, aluminum, or stainless steel. | Flat braided mesh made of machine-braided Cu-ETP1 single wires. | Flat braided mesh made of machine-braided Cu-ETP1 single wires. |
| Cross-sections | As required | 25 to 240 mm² | 6 to 70 mm² |
| Connections | Solid press-welded connections, mechanically pressed sleeves, or standard cable lugs. | Press welded joints across the entire joint cross-section. | Press welded joints across the entire joint cross-section. |
| Insulation | Pull-over or shrink sleeves according to customer requirements. | Resistant insulation for high operating voltages, UL approved. | None. |
| Alloy | Blank, tin-plated, nickel-plated, or silver-plated. | Blank. | Tinned. |
Braided Flexible Busbars for High Current Applications
Braided Flexible Busbars (LICU) are the most reliable solution when rigid busbars reach their limits. Braided Flexible Busbars are used, for example, as moving elements in switchgear and apparatus engineering and can be used in demanding environments with vibrations and movements. They enable the transmission of particularly high currents between moving components and reliably compensate for three-dimensional movements. Round strands in particular offer high flexibility in all directions of movement. Braided Flexible Busbars are customized solutions and are manufactured in various dimensions according to customer requirements.
Ultraflexx® as an alternative to cables
Ultraflexx® have been specially engineered for demanding applications and reliably absorb vibrations and switching shocks. They are primarily used as flexible busbars in control cabinets and electronic systems and are characterized by exceptional flexibility and high-quality insulation. Their main advantage lies in their extreme flexibility in adapting to the installation space and their very low contact resistance thanks to the press-welded connections. In addition, Ultraflexx® are used in many applications where pre-assembled cables reach their limits.
Earth Braids for grounding & EMC protection
Earth Braids are used for safe earthing or grounding in electric vehicles, electronic devices, and systems. High-frequency earthing is particularly important in modern switchgear. Not only the ohmic DC resistance plays a major role here, but also the impedance, which increases with frequency. The conductor shape, total length, and connection technology are decisive factors here.
Earthing braids have a lower impedance than comparable round earthing cables and are therefore much better suited for high-frequency earthing. The welded connections ensure ideal, low contact resistance. Our earthing braids are also optimized for EMC shielding (electromagnetic compatibility).
Highly flexible customized busbars
Customized prototypes
The engineering and design of highly flexible busbars requires a careful analysis of electrical, mechanical and environmental requirements. The choice of material, connections, cross-section and insulation play a decisive role in the performance and service life of the components. Finding the optimal solution for a particular application often requires a customized process involving the production and testing of prototypes. Our experienced Engineering Team will be happy to assist you in the production of such prototypes.
Customized Service
The right highly flexible busbar for your application depends on the required current carrying capacity, flexibility, and the corresponding environmental conditions.
Contact us – we will be happy to advise you!
Getting to know fields of application
We have years of experience in engineering individual solutions for your requirements. In addition, we have the necessary “workbench” to manufacture the associated components on site.
