Storm Copper Logo and Home Page Link

 

Argentina Canada Chile Columbia Costa Rica Dominican Republic Ecuador France

Germany Spain Mexico Peru Puerto Rico United Kingdom (Great Britain) United States Venezuala

 

Storm Copper saves OEMs time and money by incorporating all fabrication processes under one roof.
OEM Copper Parts
Request a Quote to specify copper parts for custom fabrication.

OEM HOTLINE
1-800-394-4804

Storm also sells standard sizes of flex braid at its online store that ship within
3-5 working days!

Explore Storm Copper's
Products and Services

Fabricated Copper Parts

OEM Copper Parts
OEM Copper Parts Chick on arrow fom info on OEM copper parts.
Copper Bus Bar Fabrication
Copper Bus Bar Click on arrow for info on copper bus bar.
Ground Bars and Bus Bar Kits
Copper Ground Bars and Kits Click on arrow for info or to order copper ground bar and kits.
Flexible Braided Connectors
Braided Flex Connectors Click on arrow for info on braided flex connectors.
Laminated Bus Bar
Laminated Bus Bar Click on arrow for info on laminated bus bar.
Epoxy and Fluidized Bed Powder Coated Bus Bar
Powder Coated Bus Bar Click on arrow for info in powder coated bus bar.
Battery Connectors, Straps and Posts
Battery Connectors & Straps Click on arrow for info on battery connectors & straps.
 
Want to see more?    

Flexible Electrical Connectors Guide

 
Storm Copper offers several braid and plating options for flexible braided connectors. Please download our PDF to view an in-depth look at these options and more.
Flexible Electrical Connectors PDF
   

Afterward, contact us and we'll connect you with one our design experts who can help get your project off the ground in less time and with all bases covered.

Can't wait? Call call our OEM Hotline now!
1-800-394-4804

 

Copper Metal Distribution

Storm Copper offers full custom copper fabrication
plus the convenience of online shopping for
copper and other components, including standoff
insulators, ground rods and more.

Copper Sheet
Copper Sheet Click on arrow for info or to order copper sheet metals.
Copper Bar Stock
Copper Bar Click on arrow for info or to order copper bar stock.
Copper Flashing
Copper Rod - Round and Square
Copper Rod Click on arrow for info or to order copper rod.
Copper Electrical Tube
Copper Tubing - Electrical Click on arrow for info or to order copper electrical tubing.
Copper Plate
Copper Plate Click on arrow for info or to order copper metal plate.
Copper Clad Ground Rods and Clamps
Ground Rods and Clamps Click on arrow for info or to order copper ground rods and clamps.
MaxiFlex Flexible Insulated Bus Bar Flexible Insulated Bus Bar Click on arrow for info or to order flexible insulated bus bar.
Electrical Standoff Insulators Electrical Insulators Click on arrow for info or to order electrical insulators.
  Standoff Insulators - Poly Click on arrow for info or to order electrical insulators made of molded polyester.
  Standoff Insulators - Ceramic Click on arrow for info or to order electrical insulators made of ceramic glass.
  Standoff Insulators - Metric Click on arrow for info or to order electrical insulators in mtric sizes.
  Insulating Tape and Sheet Click on arrow for info or to order insulating tape and sheet.
   
   
  DUNS: 62-393-3397
NAICS: 332116
CAGE/NCAGE: 1Y2K0

 

 

OEM Contact:


Customer Service Manager
240 Industrial Park Lane
Decatur, TN 37322
1-800-394-4804
FAX 423-334-3389

email: busbar@stormcopper.com

Online Store: 1-866-716-9773

For current pricing on Storm's - IN-STOCK - Copper Bar, Copper Sheet, Ground Bars, Punched Copper Connectors, Cable Jumpers and Standoff Insulators Visit our Online Store

For wholesale and volume copper metal product purchases Call Michelle Hurt at 1-866-716-9773.

 

Become A Fan!

Tin-Plated Copper Flex Braid

Flexible Electrical Connectors

Shop online NOW for copper flex braid, electrical jumpers or grounding straps.

Use our Custom Flex Braid Quote Form to send a print or fill in your specifications!

 

Custom and standard flex-braid manufactured in house.

Electrical engineers in power generation are aware of this simple fact: Vibration is an enemy of electrical connectivity.

Generators, turbines and transformers are the prime culprits, causing vibration at key distribution points in electrical power plants, substations and industrial plants. While upkeep and synchronization can reduce the scale of vibration from generators and turbines, the remaining vibration takes its toll over time, as loose connections result in a loss of performance, equipment failure and expansion from heat that dramatically increases the chance of fire. Even with the addition of dampening pads and mounts, vibration still occurs throughout these power distribution networks, loosening lugs and other connectors attached to rigid electrical connectors, like busbars and grounding bars.


Flexible electrical connectors solve high-voltage connectivity problems created by vibration from generators and transformers.

When used as the initial connector from vibration-producing equipment to a power distribution network, flexible connectors (or flexible braided jumpers) isolate the main electrical grounding bus work from the cause of vibration.

And while flexible braided connectors are more expensive than using copper bus bar, flex braid returns the investment by cutting the potential cost of down time, maintenance and energy loss created by loose electrical connections.

In addition to the positive aspects of flex braid, the most advantageous feature of this versatile connector is evident in its name – flexibility.

 
Flexible Braided Copper Electrical Connectors

A cable or cable harness with the same current-carrying capacity is much stiffer and unwieldy. A cable that will carry 750 amps is fairly easy to work in 20-foot lengths, but bending a shorter piece and routing it around other objects becomes very difficult. In addition to their stiff, unwieldy nature, cables are rigid and transmit vibration.

2-Hole Tinned Copper Flex Braid

Choosing the right flex braid.

When purchasing flex braid there are several factors that need to be addressed. The first factor that impacts a flex braid purchase is the ampacity that must be achieved and maintained. Ampacity is the maximum amount of electric current that a wire, cable or braid can carry without experiencing immediate or gradual deterioration or exceeding its temperature rating.  Another term that is often used is current rating or current-carrying capacity.

Once ampacity is determined, the next set of questions address the physical design factors. You’ll need to know what hole pattern will be required on both ends, the distance between the holes and the length from end to end. The next critical factor is width, is often a limiting factor and is most often impacted by ampacity. Higher rated braids tend toward wider configurations. Storm stocks flat flex braid in sizes ranging from #6 all the way up to 4/0. When the larger sizes are too wide for the physical limitations of an application, multiple layered flex braids are created to reach the correct design load.

Another element of braids is the stranding pattern. The number of strands and the size of strands are pre-determined by the manufacturer for each size of braid. Custom stranding is very expensive and generally not desirable when there are so many standard options available. Braid comes in bulk from the manufacturer with markings that indicate its qualities. A designation of 24-30 means that the braid is made of 24 strands of 30-gauge wire. The higher the gauge number, the finer the wire.

 

Flat vs. Round Braid…

Storm Copper stocks a very large inventory of both round and flat copper braid to reduce lead times for OEM customers.

• Typically, flat copper braid is used more often because it works well in vertical applications or direct connections where horizontal flexibility is not an issue. Flat braid also has a lower profile and takes up less room in tight quarters.

• When horizontal flexibility is specified, round copper braid is used because it bends and flexes equally in any direction.

Reaching the correct ampacity for a given application is also achieved through multiple layers of copper braid. Multiple layers of braid are selected based on total amperage requirements or current density then assembled in a parallel or stacked format according to a customer’s application.

Copper from end to end: Heavy-duty presses are then used to compress the ends of multiple layers into copper ferules. The next task is punching a hole for the connection. Punching is the most economical option, but drilling specific diameters is available and can be readily supplied upon request. Ferrules and holes are rounded on the edges for a solid connection that will not chafe or sever the strands of the braid.

Storm uses tin plated flex braid to ensure maximum protection in a number of environmental conditions, but the question of tinning or plating the ferruled ends is up to the customer and individual applications. The deciding factor to tin-plate the ends is based on the question: What kind of surface will the flex braid be connected to? Matching metals avoids the hazards of galvanic corrosion taking place where two dissimilar metals are in contact. Plated ferrules also eliminate the need for surface preparation and the use of “NO-OX” when they are mated to a plated connector.

Flexible Braided Connectors meet a wide range of applications.

Our design experts work hand in hand with OEM designers and engineers to ensure success. Plus all parts are clearly marked for efficient installation.

 

Storm design experts working hand in hand with OEM engineers.

 

Flexible copper electrical connector..

Standard Flex Braid Specifications Chart - Note: Ampacity Ratings (below) are based on Conductors in Free Air / Ambient Temperature of 30 degrees C (86F). continuous-use temperature rating.

Part Number
Braids
L
C
T
D
E
K
N
Circular Mils*
Ampacity
SC-BD (12-48)
1
12-48
0.94
0.14
2.5 - 3.0
1.25 - 1.75
0.44 - 0.56
0.62
76800
190
SC-BF (12-48)
1
12-48
1.19
0.28
3.0
1.5 - 1.75
0.44 - 0.56
0.62 - 0.75
168000
360
SC-BE (12-48)
1
12-48
1.5
0.21
3.0
1.5 - 1.75
0.44 - 0.56
0.62 - 0.75
211200
375
SC-BG (12-48)
2
12-48
0.94
0.23
2.5 - 3.0
1.25 - 1.75
0.44 - 0.56
0.62
144000
380
SC-B2D (12-48)
3
12-48
1.19
0.27
2.5 - 3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
259200
470
SC-B3D (12-48)
2
12-48
1.62
0.35
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
336000
550
SC-B2E (12-48)
2
12-48
1.19
0.35
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
422400
600
SC-B2G (12-48)
4
12-48
1.19
0.34
2.5 - 3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
345600
600
SC-B3E (12-48)
3
12-48
2.0
0.28
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
460800
700
SC-B3F (12-48)
3
12-48
1.44
0.52
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
633600
820
SC-B4E (12-48)
4
12-48
1.77
0.39
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
499200
850
SC-B3G (12-48)
3
12-48
1.69
0.59
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
921600
960
SC-B4F (12-48)
4
12-48
1.50
0.69
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
844800
1000
SC-B4G (12-48)
4
12-48
1.69
0.83
3.0
1.25 - 1.75
0.44 - 0.56
0.62 - 0.75
1344000
1200
 

* Circular Mils are equal to the area of a circle with a diameter of one thousandth of an inch - or one mil - referring to the area of the cross section of a wire or cable with a circular cross section, as the area in circular mils can be calculated without reference to pi.

Electricians in the US are familiar with the circular mil because the National Electrical Code uses the circular mil to define wire sizes larger than 4/0 AWG. The area in circular mils, A, of a circle with a diameter of d mils, is given by: A = d2

In wire gauge (cable sizing), the acronym MCM or kcmil means a thousand circular mils, the area of a wire ≈ 31.62 mils (which is 0.03162 inches) in diameter.

 

HOME | ABOUT US | CONTACT US | DIRECTIONS | SEND A PRINT | SITE MAP | GLOSSARY

© 2011 - 2012 Storm Copper Components, Co.