|Product type||Copper jumper|
|Type||Copper laminated flexible jumpers|
Copper Laminated Flexible Jumper is manufactured by stacking several foils of electrolytic copper and then applying high current under high pressure. This is a special metal diffusion whereby the metal itself melts and forms homogenous bonds thus giving a very negligible, almost nil, mill volt drop across the connector, thereby reducing the temperature rise and increasing the current carrying capacity of the jumper. In this process, no filler metal is used to join two layers together. They have a constant cross-section over the whole length. The current carrying capacity of the solid bus bar and copper laminated jumper manufactured by this process is the same. Therefore Laminated Copper flexible Jumper is a substitute for solid bus bar.
Copper flexible jumper are Manufactured in all possible shapes & sizes as per customer’s requirements.
Copper laminated flexible jumpers are manufactured by laminating high conductivity, electrolytic grade copper foils. These laminated foils are then sweated or pressure welded/fused as per customer’s requirements. Such copper jumpers carry the same current as that of Bus bars as they have a constant cross-section over the whole length giving a nil millivolt drop. So these jumpers are the best substitute for solid bus bars.
Our Copper laminated flexible jumpers are widely used in following Industries: Transformers switchgear’s, power plants, Electric locomotives, furnaces, chemical plants, electricity boards & all current carrying equipment manufacturing Industries.
It is also possible to drill, saw, braze, mill & weld the contact areas without any problem. These types of flexible connectors are used as flexible expansion joints in order to connect bus bars in Switchgear industries.
Copper laminated flexible jumpers are used as expansion connectors to prevent damages by other parts of machines or switch gears and to take care of thermal and dynamic stresses caused by the short-circuit current in the system. These jumpers have to realize movements inside machines and switchgear.Flexible Copper Laminate jumper is individually designed and manufactured keeping in view the user’s requirement and application. We also offer jumpers with contact area electro tinned, silver or gold plated to give perfect contact.
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Minimum Order Quantity: 10 onwards
|Thickness||0.035 to 0.3 mm|
|Coating||Tinned, Silver plated or Gold plated|
|Plating||99.99% pure copper|
We are the biggest and largest manufacture, export, Suppliers of Copper Laminated Flexible Shunts. It is custom designed to customer requirements and specifications and are available in any hole pattern or size. The secondary conductor strips are of High Conductivity Copper. Terminal ends can either be deep riveted or solder dipped to allow a more positive current transfer area for improved efficiency.
They are manufactured by stacking several foils of Electrolytic Copper and then forging it by applying high current under high pressure.This is a special metal diffusion process whereby the metal itself melts and forms homogenous bond thus giving a very negligible, almost nil millivolt drop across the connector, thereby reducing the temperature rise & increasing the current carrying capacity of the jumper. In this process, no filler metal is used to join layers together. They have a constant cross-section over the whole length. The current carrying capacity of a solid bus bar and Copper laminated jumper manufactured by this process is same. Therefore these jumpers are a substitute of a solid bus bar. It is also possible to drill, saw or mill the contact areas without any problem.
These type of flexible connectors are used as flexible expansion joints in order to connect bus bars in Switchgear Industries, Power Plants, Caustic Soda & Chlorine Plant using Mercury Cell, Modular Cell, Membrane Cell, Diaphragm Cell, Hydrochloride Cell, Manganese Dioxide Cell and Cathodic Protection, Bus Ducts, Transformer, V.C.B., Resistance welding equipment, Electric Locomotives, Furnaces etc. to prevent damages by other parts of machines or switchgear. These kinds of jumpers have to realize movements inside machines and switchgear. These jumpers are individually designed and manufactured keeping in view, the user requirements and application. We also offer jumpers with contact area electro - tinned, Silver plated or Gold plated to give perfect contact.
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|Wire Diameter||0.05mm(47swg) to 0.3mm(30swg)|
|Range||4 sq.mm and above|
|Single Strand Diameter||0.5 mm to 0.05 mm|
Copper Flexible Connector / Tinned Copper Flexible Connector can be made from electrolytic copper Cu-ETP (grade C101) or from oxygen free copper
Copper Flexible Connector / Tinned Copper Flexible Connector Finish:
Our wide range of copper braid products is available in the following copper wire finishes:
Model details of Copper Flexible Connector / Tinned Copper Flexible Connector:
Nominal area MM2
Dimension (Width X Length)
10 x 1.00
12 x 1.00
15 x 1.50
19 x 2.00
25 x 3.00
25 x 3.50
30 x 4.50
32 x 5.00
Even though many of our products are standard items, we also make special tailor made products made exactly to the requirements of our customers.
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|Material||High conductivity Copper Bar|
|Energy lost||8 W lost at 500 A|
|Cross-sectional area||10 mm2|
Our range of Earthing Lightning Protection also includes Copper Busbar. In electrical power distribution, a bus bar is a strip of copper or aluminum that conducts electricity within a switchboard, distribution board, substation or other electrical apparatus.
Shape / Size:
Silver, tin or nickel plating for copper bus bars is necessary in high temperature applications. At DC there is some controversy as to which plating is the best because while silver has the highest conductivity, it is also more noble than copper so it will actually accelerate corrosion wherever the plating gets scratched. Thus, you don't want to just use toothed lock washers, for example, in between a nut and the bus bar (i.e. - use a flat washer, too).
Tin plating is an excellent solution practically speaking, because it protects the copper, has reasonably low resistance (higher than silver or copper but lower than nickel) and can be easily applied yourself using "electroless" plating kits such as "TINNIT".
Tin (non-lead bearing) solder can work, but it may sweat at a higher temperature. Having someone with a hobby plating set-up will make it work better. Alternatively, buying a hobby plating transformer and some acid and cyanide will provide you the ability to do it at will. Nickel is the metal of choice. It is used to 'flash' the copper bar material, prior to plating with silver, and thus prevent corrosion by 'sealing the surface of the copper. Then fine silver is used to do the final plate, but the copper is a naturally oxidizing metal, that is why it is noted for its 'green patina' and why the planet Venus is considered the Goddess of Copper. If it is just straight plated with silver, it would be useless as the corrosion will start and the bar will blister with copper oxide and shed the silver. Nickel and silver don't melt like tin will at a temperature under 1000 degrees. (Nickel = @1100 deg f, Silver = 1470 deg f)
If you have access to a good metal cutting blade and jig-saw or a scroll-saw with a metal cutting blade, buy a sheet in the desired thickness. It's cheaper and you can customize your needed 'bar'. You can then also use a propane torch to 'anneal the copper to work or bend it. A hand drill with some good sharp bits will always provide good puncturing capabilities for necessary holes.
If using it for battery terminals, make sure the batteries are well secured and the battery boxes are solid so that the batteries do not shift around or flex relative to each other during driving. Favour a bus bar that is fairly thin but wide (to get enough conductivity) and design them with "kinks" in the middle so that they can allow slight movement between the batteries.
Note: Copper Bus Bar (Hard Drawn / Soft Drawn / Half Hard) Tinned Copper Bus Bar also available.
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Minimum Order Quantity: 50 piece
|Country of Origin||Made in India|
|Coating||99.99% pure Silver electro plated copper|
|Surface finish||Copper laminated|
|Thickness||0.05 mm - 0.3 mm|
We offer the finest quality Copper Laminated Flexible Connector that is manufactured by stacking several foils of electrolytic copper and then applying high current under high pressure. These types of flexible connectors are commonly used as the flexible expansion joints for connecting the bus bars in different applications.
These Copper Laminated Flexible Connectors are produced from high conductivity electrolytic grade copper foils/sheets. We follow various methods to produce these flexible jumpers.
Copper laminated flexible Connectors consist of several stacked strips with riveted or welded contact areas. They have a constant cross-section over the whole length. Bus bars and laminated connectors with the same cross-section can be loaded with the same current. A part of laminated connectors is utilized as flexible expansion connectors in order to connect bus bars of switch gears, transformers, generators, etc. Thanks to their elasticity, thermal expansion of bus bars are being compensated.
Most of the parts are being used as expansion connectors to prevent damages by vibration caused by switchgear operations. Another part is utilized as flexible components inside parts of machines (Like welding machines or switch gears). This kind of connectors has to realize movement inside machines and switch gears. To manufacture suitable connectors for the various applications we have different methods of production.
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