When a rigid bar is inappropriate, reliable interconnection flexibility is readily provided by factory-assembled laminates, braids or cables.
- Laminated-sheet conductors present neat appearance and carry a current density comparable to solid bars. They permit restricted bending or twisting, enhanced with an integral double bend, and have ends consolidated by soldering or, when aligned by an outer sleeve, by their connection fasteners. A triple-bend ‘VEE’ accommodates extra axial offsets.
- Flexible braids provide more flexibility than laminates but are limited in trans-axial thermal characteristics. Terminations provided by punching through a flattened end-collar require solder-consolidation, or the tightened fastener, to stabilise contact integrity. Insulation and identification-labelling can be provided by sleeving.
- Depending on length, the comparatively low cost of bulk-produced insulated cables with factory-applied terminations provide an economic level of reliable flexible interconnection.
- High-specification cables (e.g. for safety-earthing) can be achieved with detailed attention to cable-specification and termination design.
- There are important issues surrounding the effects of high temperatures and thermal cycling on both applied terminations and the resistivity of coated strands within cables or braids. Please request further information.
- Insulation can be applied by sleeving, laminated-film or coating.
- High-frequency (≥10kHz) or pulse (≤100µS) operation imposes conductance limitations which can only be resolved with inter-laminated conductors or litzen-drehen (strands-rotating) wires. Please request further advice or detail on this.
- We are happy to discuss the general strengths and weaknesses of structural, material and fastening specifications and can recommend, and test, limitations on current capacity and ambient conditions.