PVC Flexible Copper Stranded Wire

In the modern industrial ecosystem, a seemingly simple PVC Flexible Copper Stranded Wire is, in fact, a sophisticated product resulting from the high-level integration of material science and precision engineering. As a leading manufacturer in this sector, Shaoxing Sweld Electric Co., Ltd. understands that high-quality wire must do more than just “conduct electricity.” It must maintain zero performance degradation throughout a decade-long service cycle, even when subjected to complex dynamic environments and extreme temperatures.

How Do Precision Wire Drawing and Annealing Processes Define “Extreme Flexibility”?

In the production system of a PVC Flexible Copper Stranded Wire Factory, flexibility is not an accidental physical attribute; it originates from extremely rigorous control over metal drawing and heat treatment. Within the modern workshops of Shaoxing Sweld Electric Co., Ltd., the birth of every high-performance wire begins with the micron-level deep processing of high-purity Oxygen-Free Copper (OFC) rods.

Copper purity is the cornerstone of electrical conductivity, but the drawing process is the key determinant of the wire’s mechanical lifespan. We utilize multi-stage large, medium, and fine continuous drawing units to gradually reduce 8mm copper rods to micro-filaments with diameters as small as 0.05mm to 0.20mm. During this process, the metal undergoes intense plastic deformation, causing internal lattice distortion and fragmentation—a phenomenon known in material science as “work hardening.” If handled improperly, the copper wire becomes exceptionally brittle and hard, making it prone to snapping during subsequent stranding or installation.

To counteract this hardening effect, Shaoxing Sweld Electric Co., Ltd. has invested heavily in developing In-line Continuous Annealing technology. On our automated production lines, the copper wire enters a controlled heating zone immediately after drawing, undergoing precise heat treatment within a protective gas atmosphere. We use a PID closed-loop control system to ensure the annealing temperature remains strictly within the optimal recrystallization range for the metal. This not only endows the copper wire with a high elongation rate, allowing it to withstand repeated bending without micro-cracks, but also ensures the long-term stability of its electrical conductivity.

For a flexible wire factory, consistency in individual filament diameter tolerance directly affects the resistance distribution of the final cable. We have installed laser diameter gauges at every drawing die station to provide real-time feedback compensation. This pursuit of microscopic detail ensures that every filament produced by Shaoxing Sweld Electric Co., Ltd. possesses uniform tensile strength and suppleness, laying a solid physical foundation for the complex compound stranding processes that follow.

How Does Multi-Strand Compound Structure Guarantee Electrical Stability Under High-Frequency Vibration?

Once the individual filaments are processed, the next step is to combine these hair-thin copper wires into a cohesive unit with high current-carrying capacity and extreme softness—this is the artistry of the stranding process. As a professional factory, Shaoxing Sweld Electric Co., Ltd. knows that simple bundling-style stranding cannot meet the demands of industrial-grade dynamic applications.

We employ “Precision Helical Stranding” technology. By simulating fluid dynamics and mechanical stress models, our engineers design scientific stranding pitches for various wire specifications. The “pitch” refers to the axial distance a single copper wire moves while rotating once around the central axis. A smaller pitch enhances flexibility but slightly increases resistance; a larger pitch results in a looser structure. The engineering team at Shaoxing Sweld Electric Co., Ltd. has conducted thousands of experiments to find the “Golden Ratio” between current transmission efficiency and mechanical flexibility.

In high-frequency vibration scenarios—such as New Energy Vehicle (NEV) power systems, industrial robot joints, and automated drag chains—ordinary rigid wires suffer from stress fatigue, eventually leading to “stress concentration fractures” at the connection terminals. However, the compound stranded structure produced by Shaoxing Sweld Electric Co., Ltd. functions like a rope. Through minute relative sliding between individual copper strands, it effectively dissipates and absorbs external vibration energy across the entire wire body.

Furthermore, our stranding process emphasizes “Structural Compactness.” During stranding, we use synchronous tension controllers to ensure that both the inner and outer layers of copper wire are under uniform stress. Uneven tension can cause “bird-caging” or internal collapsing, leading to diameter deviations that interfere with the subsequent PVC extrusion. Through this precise geometric control, our products provide a larger effective contact area when paired with crimp terminals, significantly reducing contact resistance. This technical detail effectively suppresses terminal overheating during long-term, high-current operation, safeguarding the electrical safety of the entire system.

How Does Eco-Friendly PVC Extrusion Balance Dielectric Strength with Installation Convenience?

The final line of defense for a wire is its insulation layer. Within the factory of Shaoxing Sweld Electric Co., Ltd., PVC (Polyvinyl Chloride) is no longer just a plastic; it is a composite protective material that has been specially modified. As an industry veteran, we have developed dozens of exclusive PVC formulations tailored to different industrial applications.

The core of the insulation extrusion process lies in the balance between “concentricity” and “adhesion.” Utilizing high-precision cross-head extruders, we ensure that the conductor is positioned precisely at the geometric center of the insulation layer. If eccentricity occurs, the wire becomes vulnerable to localized dielectric breakdown under lateral pressure or voltage surges. The in-line eccentricity measurement systems at Shaoxing Sweld Electric Co., Ltd. monitor production in real-time, ensuring that our eccentricity rates are far below national standards, providing customers with an extra margin of safety in high-voltage environments.

Regarding physical properties, our PVC insulation materials are infused with high-performance anti-aging agents and plasticizers. This ensures the cables remain supple at frigid temperatures (down to -20°C) without cracking, while maintaining excellent mechanical strength at high temperatures (up to 105°C). Additionally, to improve assembly efficiency for our downstream customers, we have developed “Easy-Strip” technology. By controlling the interfacial adhesion between the PVC layer and the tin-plated copper core, operators can easily remove the jacket using automated stripping machines without damaging the delicate internal copper filaments. This greatly reduces production scrap rates.

Most importantly is our commitment to the environment. As a company with a global vision, all PVC Flexible Copper Stranded Wire from Shaoxing Sweld Electric Co., Ltd. have passed rigorous RoHS 2.0 and REACH testing. We strictly exclude harmful substances such as lead, cadmium, and phthalates, ensuring that our products not only enter high-end markets in Europe and North America but also contribute to the global mission of green manufacturing.

To help you clearly evaluate our manufacturing advantages, please refer to the following table: