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Application
- Aerospace & Aviation
- Low-Voltage Electrical (Electric Brush Wires）
- Chemical & Metallurgical Engineering Equipment
- Industrial Machinery & Equipment Clusters
- Superconducting Technology Applications
- Rail Transit Equipment
- Smart Grid & Power Transmission/Distribution Applications
- New Energy Wind Power
- Power Storage Equipment
- New Energy Vehicle Systems
- Products
Electric Brush Wires with Spot-Welded Ends - High-Quality Conductors from China Suppliers & Factory
Technical Data
Material
Annealed Cu-ETP wires, C11000, copper content ≥ 99.95%
Finish
Bare, tin plating
Packing Modes
In rolls, on spools or wooden drums
Product Display
Type And Specification
| Type | Single Wire Diameter | Elongation, not less than |
|---|---|---|
| BGTS | 0.10mm (AWG38), 0.12mm | 18% |
| BGTSX | 0.10mm (AWG38), 0.12mm | 15% |
| BGTSR | 0.05mm (AWG44), 0.07mm(AWG41) | 15% |
Model And Meaning
Technical Specifications & Customization
Single Wire Diameter: 0.12mm / 0.10mm Series
| Part No. | Nominal Cross Section (mm²) | Calculating Cross Section (mm²) | Structure | Calculating Outside diameter (mm) | Max. DC Resistance at 20℃ (Ω/km) | Calculating weight (kg/km) | ||
|---|---|---|---|---|---|---|---|---|
| Total Wire Number | Strands × Wire Number Per Strand / Single Wire Diameter (mm) | BGTS | BGTSX | |||||
| BGTS(X)-6.3 | 6.3 | 6.24 | 552 | 12×46/0.12 | 4.3 | 2.94 | 3.07 | 59.1 |
| BGTS(X)-8 | 8.0 | 7.87 | 696 | 12×58/0.12 | 4.8 | 2.33 | 2.44 | 74.9 |
| BGTS(X)-10 | 10 | 10.04 | 888 | 12×74/0.12 | 5.3 | 1.83 | 1.91 | 95.1 |
| BGTS(X)-12.5 | 12.5 | 12.46 | 1102 | 19×58/0.12 | 5.9 | 1.48 | 1.55 | 118.5 |
| BGTS(X)-16 | 16 | 15.90 | 1406 | 19×74/0.12 | 6.7 | 1.16 | 1.21 | 151.2 |
Single Wire Diameter: 0.10mm (AWG38)
| Part No. | Nominal Cross Section (mm²) | Calculating Cross Section (mm²) | Structure | Calculating Outside diameter (mm) | Max. DC Resistance at 20℃ (Ω/km) | Calculating weight (kg/km) | ||
|---|---|---|---|---|---|---|---|---|
| Total Wire Number | Strands × Wire Number Per Strand / Single Wire Diameter (mm) | BGTS | BGTSX | |||||
| BGTS(X)-1 | 1 | 0.99 | 126 | 7×18/0.10 | 1.4 | 18.5 | 19.3 | 9.5 |
| BGTS(X)-1.4 | 1.4 | 1.37 | 175 | 7×25/0.10 | 1.7 | 13.2 | 13.7 | 12.5 |
| BGTS(X)-1.5 | 1.5 | 1.48 | 189 | 7×27/0.10 | 1.8 | 11.9 | 12.7 | 14.0 |
| BGTS(X)-1.8 | 1.8 | 1.75 | 224 | 7×32/0.10 | 2.0 | 10.2 | 10.7 | 16.5 |
| BGTS(X)-2 | 2 | 1.98 | 252 | 7×36/0.10 | 2.2 | 9.23 | 9.65 | 19.5 |
| BGTS(X)-2.5 | 2.5 | 2.53 | 322 | 7×46/0.10 | 2.4 | 7.39 | 7.72 | 25.0 |
| BGTS(X)-3 | 3 | 2.97 | 378 | 7×54/0.10 | 2.7 | 6.16 | 6.43 | 29.5 |
| BGTS(X)-4 | 4 | 3.96 | 504 | 7×72/0.10 | 2.8 | 4.62 | 4.83 | 38.0 |
| BGTS(X)-5 | 5 | 4.94 | 630 | 7×90/0.12 | 3.2 | 3.69 | 3.86 | 47.6 |
| BGTS(X)-6 | 6 | 5.93 | 756 | 12×63/0.10 | 3.7 | 3.01 | 3.23 | 58.5 |
| BGTS(X)-6.3 | 6.3 | 6.24 | 552 | 12×46/0.12 | 4.3 | 2.94 | 3.07 | 59.1 |
| BGTS(X)-8 | 8 | 7.91 | 1008 | 12×84/0.10 | 4.2 | 2.33 | 2.44 | 75.5 |
| BGTS(X)-9 | 9 | 8.95 | 1140 | 12×95/0.10 | 4.4 | 2.05 | 2.15 | 87.0 |
| BGTS(X)-10 | 10 | 8.89 | 1260 | 12×105/0.10 | 4.8 | 1.83 | 1.91 | 97.2 |
| BGTS(X)-12 | 12 | 11.97 | 1524 | 12×127/0.10 | 5.4 | 1.50 | 1.62 | 117.0 |
| BGTS(X)-16 | 16 | 15.90 | 2025 | 15×135/0.10 | 6.2 | 1.16 | 1.21 | 156.0 |
Round Type: Single Wire Diameter: 0.07mm (AWG41)
| Part No. | Nominal Cross Section (mm²) | Calculating Cross Section (mm²) | Structure | Calculating Outside diameter (mm) | Max. DC Resistance at 20℃ (Ω/km) | Calculating weight (kg/km) | ||
|---|---|---|---|---|---|---|---|---|
| Total Wire Number | Strands × Wire Number Per Strand / Single Wire Diameter (mm) | BGTSR | BGTSRX | |||||
| BGTSR(X)-2 | 2 | 1.93 | 504 | 7×72/0.07 | 2.2 | 9.16 | 9.65 | 18.3 |
| 1.93 | 504 | 7×3×24/0.07 | 2.2 | 9.16 | 9.65 | 18.6 | ||
| BGTSR(X)-3.5 | 3.5 | 3.47 | 903 | 7×3×43/0.07 | 2.7 | 5.35 | 5.51 | 33.3 |
| BGTSR(X)-4 | 4 | 4.01 | 1044 | 12×3×29/0.07 | 2.9 | 4.59 | 4.83 | 39.0 |
| 4.03 | 1050 | 7×3×50/0.07 | 3.0 | 4.59 | 4.83 | 39.0 | ||
| BGTSR(X)-5 | 5 | 4.84 | 1260 | 7×3×60/0.07 | 3.2 | 3.71 | 3.86 | 46.5 |
| 5.02 | 1305 | 15×3×29/0.07 | 3.2 | 3.71 | 3.86 | 48.5 | ||
| BGTSR(X)-6 | 6 | 5.65 | 1470 | 7×3×70/0.07 | 3.6 | 2.93 | 3.21 | 54.2 |
| BGTSR(X)-8 | 8 | 7.75 | 2016 | 12×3×56/0.07 | 4.2 | 2.33 | 2.44 | 73.0 |
| BGTSR(X)-10 | 10 | 9.69 | 2520 | 12×3×70/0.07 | 4.8 | 1.83 | 1.91 | 90.5 |
| BGTSR(X)-12 | 12 | 11.90 | 3096 | 12×3×86/0.07 | 5.4 | 1.50 | 1.60 | 112.2 |
| BGTSR(X)-16 | 16 | 15.34 | 3990 | 19×3×70/0.07 | 6.2 | 1.16 | 1.21 | 150.5 |
Round Type: Single Wire Diameter: 0.05mm (AWG 44)
| Part No. | Nominal Cross Section (mm²) | Calculating Cross Section (mm²) | Structure | Calculating Outside diameter (mm) | Max. DC Resistance at 20℃ (Ω/km) | Calculating weight (kg/km) | ||
|---|---|---|---|---|---|---|---|---|
| Total Wire Number | Strands × Wire Number Per Strand / Single Wire Diameter (mm) | BGTSR | BGTSRX | |||||
| BGTSR(X)-1 | 1 | 0.99 | 504 | 7×3×24/0.05 | 1.4 | 18.5 | 19.3 | 9.3 |
| BGTSR(X)-1.3 | 1.3 | 1.32 | 672 | 7×3×32/0.05 | 1.7 | 14.2 | 14.8 | 12.5 |
| BGTSR(X)-1.5 | 1.5 | 1.48 | 756 | 7×3×36/0.05 | 1.8 | 11.9 | 12.7 | 14.0 |
| BGTSR(X)-1.8 | 1.8 | 1.81 | 924 | 7×3×44/0.05 | 2.0 | 10.2 | 10.7 | 17.5 |
| BGTSR(X)-2 | 2 | 1.98 | 1008 | 7×3×48/0.05 | 2.2 | 9.16 | 9.65 | 19.0 |
| BGTSR(X)-2.5 | 2.5 | 2.30 | 1176 | 7×3×56/0.05 | 2.3 | 7.39 | 7.72 | 22.5 |
| BGTSR(X)-3 | 3 | 2.95 | 1505 | 7×5×43/0.05 | 2.6 | 6.16 | 6.43 | 29.0 |
| BGTSR(X)-4 | 4 | 3.95 | 2016 | 12×3×56/0.05 | 2.7 | 4.59 | 4.83 | 39.0 |
| BGTSR(X)-5 | 5 | 4.94 | 2520 | 15×3×56/0.05 | 3.2 | 3.71 | 3.86 | 48.5 |
| BGTSR(X)-6 | 6 | 6.26 | 3192 | 19×3×56/0.05 | 3.6 | 2.93 | 3.21 | 60.0 |
| BGTSR(X)-8 | 8 | 8.05 | 4104 | 19×3×72/0.05 | 4.2 | 2.33 | 2.44 | 78.5 |
| BGTSR(X)-10 | 10 | 10.00 | 5096 | 7×7×104/0.05 | 4.8 | 1.83 | 1.91 | 97.0 |
| 10.07 | 5130 | 19×3×90/0.05 | 4.8 | 1.83 | 1.91 | 97.8 | ||
| BGTSR(X)-12 | 12 | 12.08 | 6156 | 19×3×108/0.05 | 5.4 | 1.50 | 1.60 | 117.0 |
Product Advantages
- Pre-welded ends: Eliminate loose strands and reduce assembly time, ensuring consistent electrical contact in brush holders.
- Ultra-high flexibility: Micro-stranded construction (single wire down to 0.05 mm) allows tight bending radii, ideal for high-dynamic applications.
- Excellent conductivity: High-purity Cu-ETP (≥99.95%) with low DC resistance, minimizing power loss, especially under high-frequency or pulsed currents.
- Full compliance: Strict alignment with GB/T12970.4-2009 ensures traceability and consistent industrial quality.
- Customizable welding patterns: Single-end and double-end configurations available upon request.
Operating Conditions
Temperature Range
–40°C to +200°C (tin-plated version)
Environment
Dry or moderate humidity. Avoid prolonged contact with acids, alkalis, or corrosive gases. Tin-plated version can be used in mildly corrosive environments.
Current Rating
Refer to max DC resistance values in the specification table and select cross-section based on equipment heat dissipation.
Maintenance and Care
- Periodically inspect conductor surface for oxidation, blackening, or mechanical damage, especially when used in high-humidity or chemical atmospheres.
- During installation, avoid excessive tension or kinking; keep minimum bending radius no less than 5 times the outer diameter of the wire.
- For tin-plated products stored long-term, use sealed packaging and store in a dry, clean environment to prevent discoloration of the tin layer.
- In high-frequency equipment, ensure terminal crimping or soldering is secure to avoid local overheating due to high contact resistance.
After-Sales Service
- Factory inspection reports and material certificates are provided, traceable to raw material batches.
- Technical team available to assist with selection, structural optimisation, and failure analysis.
- Small batch sample orders supported; lead time for bulk orders is usually 15–25 working days (expediting possible upon request).
Customization Upon Request
Zhejiang Bridgold Copper Tech Co., Ltd. is a professional leader China carbon brush wire, highly flexible copper stranded wires, highly flexible round stranded cables, flexible copper stranded wires, Flexible Copper Stranded Wires for Electric Brush manufacturers and suppliers with high quality and low price. Welcome to contact us.
Frequently Asked Questions (FAQ)
What are the key benefits of spot-welded ends on electric brush wires?
Spot-welded ends prevent copper strands from fraying or coming loose during assembly, ensuring a robust, unified connection point that speeds up installation and guarantees stable electrical conductivity in carbon brush holders.
What copper grade is used in these flexible stranded wires?
All wires are manufactured using premium annealed Cu-ETP (C11000) with a guaranteed copper purity of ≥ 99.95%, offering low electrical DC resistance and high mechanical flexibility.
Can I order custom strand constructions or single/double welded ends?
Yes, custom single wire diameters (from 0.05 mm to 0.12 mm), tailored cross-sectional areas, packaging modes, and single- or double-end welding options are fully customizable upon request.
What is the operating temperature range for bare and tin-plated wires?
The tin-plated brush wire versions can operate stably in temperatures ranging from –40°C up to +200°C, providing enhanced anti-oxidation and corrosion resistance in humid or demanding environments.
What is the typical production lead time and sample availability?
Small batch sample orders are supported for testing and validation. Standard mass production lead times typically range from 15 to 25 working days, with expedited options available based on order requirements.