Explore our high-performance, precision-engineered flexible copper and aluminum conductive jumpers designed specifically for battery pack enclosures and power distribution modules.
The global transition toward electrification across automotive, commercial transport, and renewable energy sectors has fundamentally shifted the requirements for high-voltage power distribution. Modern Electric Vehicle (EV) battery packs—operating under 400V, 800V, and emerging 1000V+ architectures—demand robust electrical connection systems capable of handling ultra-high continuous current densities, rapid charge/discharge spikes, and persistent mechanical stresses.
In traditional power systems, rigid busbars were often utilized to transfer energy between electrical nodes. However, inside high-density EV battery enclosures and industrial Energy Storage Systems (ESS), rigid copper or aluminum components encounter severe structural limitations. Operational dynamics such as chassis torsion, road vibration, expansion and contraction due to thermal cycling, and tolerance stack-ups during automated battery module assembly can generate catastrophic stress points on cell terminals and printed circuit battery management boards. This is where Braided Flexible Connectors have emerged as the critical architectural component for automotive engineers and power design teams globally.
Multi-strand braided construction absorbs continuous micro-vibrations and heavy mechanical impacts, preventing fatigue stress on sensitive battery cell terminals.
Dynamic movement during rapid charge cycles produces thermal expansion; flexible copper jumpers flex naturally without transferring stress to surrounding hardware.
Engineered for tight space envelopes within battery module-to-module (M2M) and module-to-pack (M2P) topologies, allowing high-density cell packing.
A braided flexible connector consists of multiple fine-gauge wires (typically High-Purity C1100 Oxygen-Free ETP Copper or conductive Aluminum alloy strands) woven together into a flexible sleeve or flat braid format. The ends are compressed, molecularly welded, or outfitted with custom contact terminals using press-welding, dip-soldering, or cold-press technologies.
While rigid busbars provide structural stiffness in static electrical cabinets, inside an electric vehicle battery pack, rigidity is a liability. Thermal fluctuations cause differential expansion between battery cells and aluminum cooling plates. Flexible braided connectors accommodate axial, lateral, and torsional movement, eliminating mechanical fatigue, thermal stress cracking, and electrical arc risk over the lifetime of the vehicle (15+ years/300,000 km lifecycle).
The versatility of braided flexible connectors makes them irreplaceable across complex electrical infrastructures:
In pouch, cylindrical (2170, 4680), and prismatic battery cell assemblies, flexible braided jumpers bridge individual battery modules to master contactor units. Insulation options—such as flame-retardant silicone, PVC dipping, or cross-linked heat-shrink sleeves—ensure zero risk of thermal runaway arc propagation between adjacent channels.
Containerized commercial and utility-scale energy storage arrays rely on insulated flexible copper braided wire jumpers to connect high-capacity battery racks to central power conversion systems (PCS). These connectors handle constant charge-discharge cycling without mechanical loosening caused by thermal expansion.
Liquid-cooled high-power DC fast-charging stations (350kW to 1MW Megawatt Charging Systems) use high-flex braided copper leads inside charging cabinets and power cabinets to ensure flexible cable maneuvering while minimizing power loss across high-current paths.
Beyond passenger EVs, braided flexible connectors power electric buses, heavy electric trucks, rail transit locomotives, wind turbines, and industrial transformers where high structural vibration is present during continuous operation.
Zhejiang Bridgold Copper Tech Co., Ltd. is a national-level high-tech enterprise specializing in the research, development, design, and intelligent production of high-performance flexible conductive connection products.
Bridgold is dedicated to the intelligent manufacturing of a comprehensive range of flexible conductive products, including:
Our products are widely used in electric vehicles, energy storage systems, charging infrastructure, wind power, industrial control, rail transit, and medical equipment. With a strong focus on quality and innovation, Bridgold has built a solid reputation both domestically and internationally. Our products are sold throughout China and exported to North America, Europe, Southeast Asia, the Middle East, Africa, and beyond.
As a trusted supplier to many Fortune Global 500 companies and industry leaders, Bridgold has established long-term, stable partnerships with renowned global enterprises:
In 2010, the company entered the qualified supplier list for Siemens Healthcare and GE Wind Energy, marking a significant milestone in its global expansion. To date, our copper braided wire series products rank No.1 in global market share, a testament to our manufacturing excellence and customer trust.
In the new energy vehicle sector, our products have been successfully applied in major automotive brands such as Mercedes-Benz, BAIC, SAIC, JAC, NIO, FAW, and Great Wall Motors, ensuring the safety and performance of automotive electrical connection systems.
As of 2025, Bridgold has accumulated 51 national patents, including 16 invention patents. The company participated in the formulation of the national standard GB/T 37133 "High-voltage connection system for electric vehicles". Our core technologies cover cutting-edge fields such as superconducting connection materials, high thermal conductivity composites, and intelligent manufacturing processes.
Bridgold has established a professional copper connection technology R&D center with strong research capabilities, recognized by the Zhejiang Provincial Government as a "Zhejiang Provincial Enterprise Technology R&D Center" and "Zhejiang Provincial Enterprise Technology Center". These certifications ensure comprehensive technical quality control throughout the entire process—from raw material quality analysis and manufacturing process development to final product quality inspection.
In response to global industrial upgrading and green transformation, Bridgold continues to advance intelligent manufacturing and digital transformation. We have invested in the development and introduction of high-end manufacturing and testing equipment, building a personalized, digitalized, efficient, and standardized intelligent manufacturing system.
The company actively promotes the standardization of products and technologies by participating in the formulation of industry standards. Through industry-university-research collaboration with top universities and research institutions, we jointly tackle common technical challenges in the industry, building distinctive technological advantages for EV battery packs and next-gen power systems.
Explore our full portfolio of high-purity copper and aluminum braided, laminated, and insulated flexible connection products engineered for critical electrical systems.
Aluminum Braided Wires
Flexible Aluminum Wire Connectors
Flexible Plating Copper Foil Laminated Connectors
Flexible Copper Foil Laminated Connectors with Insulation
Flexible Copper Braided Wires
Flexible Copper Wire Connectors with insulation
Square Copper Braided Wires
Insulated Flexible Copper Stranded Wires