Copper braided jumpers are a type of electrical conductor that is created by twisting or braiding multiple thin strands of copper wire into a more compact structure. These are intended to offer dependable electrical conductivity, while offering flexibility and motion among the connected components.
Braided copper jumpers are not stiff and straight like copper bars or solid conductors, but are flexible. They are especially valuable in situations where room is limited, electrical equipment is vibrating, thermal expansion is a factor, or the equipment is subject to mechanical movement.
How Are Copper Braided Jumpers Made?
The copper braided jumpers are made by twisting several thin copper wires or strips together.
In general, the manufacturing process includes the following steps:
| Specification | Details |
|---|---|
| Material | High-Conductivity Copper |
| Copper Grade | ETP / EC Grade |
| Wire Diameter | 0.10–0.30 mm |
| Width | 10–200 mm |
| Length | Customizable |
Why Is Copper Used for Braided Jumpers?
The excellent electrical properties of copper make it one of the most common materials used for electrical jumpers.
High Electrical Conductivity
Copper has a very good electrical conductivity, and when it is properly sized, it can efficiently conduct electricity.
Flexibility
A conductor can be made very flexible by braiding fine copper strands.
Good Thermal Conductivity
Copper conducts heat well, which may be desirable in an electrical application where heat can be generated.
Reliable Electrical Connections
Copper braided jumpers can be produced with a variety of different terminals to match electrical equipment.
Long Service Life
With careful selection and installation in the operating environment, copper braided jumpers can deliver long-service life.
What Are Copper Braided Jumpers Used For?
Copper braided jumpers can be utilized in a large variety of applications.
1) Electrical Bonding
A bonding jumper is a piece of conductive material that joins two conductive parts to keep a low difference in electrical potential.
2) Grounding Connections
Grounding can also be achieved with the copper braided jumpers.
They can create conductive connections between conductive parts of equipment where a flexible connection is needed.
3) Switchgear
Multiple electrical components are present in switchgear which may need flexible electrical connections.
Copper braided jumpers can be used between:
They can be flexible, making installation easier and may help to adjust for vibration and thermal movement.
4 ) Transformers
During operation, transformers may vibrate and heat up, which causes expansion.
Flexible copper braided jumpers can allow some flexibility of movement and provide electrical connections.
5) Motors and Generators
Mechanical vibration is produced during the operation of a motor or a generator.
When equipment moves or vibrates a rigid connection might have additional mechanical stress.
6) Battery Systems
For battery and energy-storage equipment in which electrical connections must be flexible, copper braided jumpers can be used.
The jumper should be sized correctly for the application, taking into account the electrical load and operating conditions for high-current applications.
7) Electrical Panels
Copper braided jumpers work well in electrical control and distribution panels.
They can be used to join parts when space is an issue or when vibration and movement must be allowed.
8) Flange Bonding
Copper braided jumpers can be employed in some flanged connections for electrical continuity or to bond.These can impact electrical continuity.
A flexible copper jumper can offer an intentional conductive path between the two sides of the connection where bonding is called for by the system design.
9) Industrial Machinery
Industrial machinery can vibrate, move, and be under extreme operating conditions.
Copper braided jumpers can be used to connect the electrical parts and be used to reduce mechanical stress, is flexible.
10) Renewable Energy Equipment
Renewable energy and power conversion systems are also possible applications for copper braided jumpers.
Applications may include: