Flexible power connections

The copper braids are high-conductivity flexible conductors supplied as raw material in coils or reels depending on requested quantity. Manufactured from Cu-ETP copper wires (Ø 0.10 mm or Ø 0.20 mm) in accordance with UNI EN 13602, these braided conductors provide excellent electrical conductivity, flexibility and mechanical reliability and are available in several configurations to meet different installation requirements:

► Flat copper braids

► Round copper braids

► Twisted flexible copper cables

► Bare copper braids

► Tin-plated copper braids

Standard cross-sections range from 6 mm² up to 300 mm², while other conductor and/or special braid materials and structure are available on request.

The earthing braids, also known as grounding straps, are flexible copper grounding connectors designed to ensure reliable equipotential bonding and effective fault current dissipation in power distribution systems and electrical installations.

Manufactured from high-conductivity Cu-ETP copper (UNI EN 13602 – Ø 0.20 mm wires), these braids are available in bare or tinned copper versions with copper terminals, providing excellent electrical conductivity, low contact resistance and long-term durability.

Standard cross-sections range from 6 mm² up to 75 mm², with customized dimensions and terminal configurations available on request.

The braided power copper conductors, also referred to as braided shunts, flexible copper connectors, copper braid connectors or flexible busbar connections, are widely used in high-current power distribution systems.

Manufactured from high-conductivity Cu-ETP copper wires, these braided power conductors are engineered to ensure reliable high-density current transfer in critical power infrastructures where electrical performance, thermal stability and mechanical integration are essential, thus supporting flexible power distribution across modern energy systems.

With cross sections ranging from 10 mm² up to 5,000 mm² and current ratings exceeding 6,000 A, Elexo braided conductors are designed for compact installations where space constraints, vibration resistance and installation flexibility are decisive factors.

ELEXOBUS is a ready-to-install high-current flexible power link system for LV and MV applications up to 3.3 kV, designed as a flexible busbar solution and an efficient alternative to rigid copper busbar systems in demanding power distribution applications, where high current capacity, compact routing and installation simplicity are critical.

This system combines BizLink Silitherm SIF/POL silicone cable technology with Elexo’s low-resistance copper terminals, delivering a flexible, thermally optimized and easy-to-install solution for high-current electrical connections.

ELEXOPOWER HF flexible copper braids are engineered as ready-to-install connection solutions for switchboards and power distribution systems where electrical reliability, fire safety and operational continuity are essential.

These insulated flexible connectors combine the high electrical conductivity of braided copper with a halogen-free, low-smoke, self-extinguishing TPE insulation, providing safe and reliable connections for modern electrical installations.

The compact design and factory-assembled terminals simplify installation and improve operational safety, making ELEXOPOWER HF particularly suitable for switchgear, power distribution panels and critical power systems.

The crimped lug conductors are flexible copper connections manufactured with round copper braid or twisted copper cable, fitted with mechanically crimped cable lugs for fast and reliable electrical connections.

Produced from high-conductivity Cu-ETP copper (Ø 0.20/0.10 mm wires), these conductors are available in bare or tin-plated versions, ensuring excellent electrical conductivity, low contact resistance and easy integration in low-voltage power systems.

Designed for direct bolted connections, the crimped lug conductors simplify installation and provide reliable electrical contact for a wide range of industrial and power distribution applications.

Originally developed for resistance welding applications, Elexo air cooled conductors are engineered to ensure reliable high-current transfer in demanding industrial environments. Over time, they have evolved into versatile power connections used not only in welding systems, but also in heating equipment and flexible busbar connections.

Designed for reliable performance under continuous load, these flexible conductors combine high electrical conductivity, mechanical flexibility and robust insulation, ensuring stable operation in challenging operating conditions.

The laminated flexible shunts are multilayer copper connectors designed to ensure reliable high-current transfer in power distribution systems where thermal expansion, mechanical movement or installation tolerances must be absorbed without transmitting stress to the electrical equipment.

These laminated shunts are commonly used as flexible joints or busbar expansion joints in electrical systems where rigid copper bars cannot accommodate thermal expansion or mechanical movement.

Manufactured from stacked copper laminations with thickness starting from 0.1 mm, the shunts combine high electrical conductivity, controlled flexibility and excellent mechanical stability at the connection terminals.

Elexo laminated shunts are manufactured using high-quality copper materials selected according to the mechanical behavior required by the application:

► Cu-ETP (CW004A) EN 13599 R290 – for dynamic applications

► Cu-HCP (CW021A) EN 13599 R220 – for expansion and compensation systems

► Cu-ETP (CW004A) EN 13599 R220 – for static high-current connections

Aluminum laminated shunts (EN AW 1050A) are also available on request.

The insulated flexible copper busbars, also known as laminated flexible busbars, are designed for low-voltage power distribution systems where high current capacity, compact layouts and installation flexibility are required.

Manufactured from laminated Cu-ETP copper strips (UNI EN 1652), these flexible busbars combine excellent electrical conductivity with the ability to absorb vibration and compensate thermal expansion, improving the reliability of electrical connections in demanding power installations.

The black self-extinguishing insulation (UL94 V0) ensures high dielectric performance and operational safety in electrical panels and switchgear assemblies. The insulation system is UL filed and compliant with international electrical safety standards.

Supplied as flexible bars in standard 2-meter lengths, Elexo flexible busbars can also be delivered cut-to-length or preformed according to customer drawings, simplifying installation and reducing the assembly time.

The threaded copper bars are precision-manufactured Cu-ETP copper rigid busbars designed for modular low-voltage power distribution and equipotential grounding systems.

Produced in accordance with UNI EN 13601, these flat copper bars feature accurately spaced threaded holes along the length, allowing fast, secure and repeatable bolted connections without additional drilling or machining during the assembly.

With radiused edges (1 mm) and optional surface finishes such as tin, silver or nickel plating, these bars ensure excellent electrical conductivity, mechanical robustness and long-term contact reliability.

The accessories include busbar clamps, Cu-Al bimetallic transition plates and tinned copper plates, designed to ensure safe, stable and efficient connections in electrical power distribution systems.

These components support the installation and integration of copper and aluminum conductors, playing a key role in guaranteeing correct mechanical fixing, reliable electrical contact and compatibility between different conductive materials.

Elexo Cu-Al bimetallic plates are designed to provide a reliable and electrically stable interface between copper and aluminum conductors, preventing galvanic corrosion in electrical power systems, by providing a stable transition between the two materials.

The busbar insulators and spacing columns, also known as busbar support insulators or busbar standoff insulators, are used to maintain the proper insulation distances against live parts, ensuring operational safety and mechanical stability in demanding industrial environments.

Manufactured in BMC (Bulk Moulding Compound polyester resin) or glass fiber reinforced Polyamide 6, these components ensure high dielectric performance, excellent mechanical strength and certified fire resistance.