BusBar High Voltage
Products Description
BusBar High Voltages are metallic conductive connectors used in high-voltage and high-current systems, typically made of high-purity copper. Their main functions are to achieve centralized current transmission, conductive connections between equipment, and energy distribution within the system.
Compared to traditional cables, high-voltage copper busbars have the following advantages:
Higher conductivity
Lower resistance loss
More stable heat control
More compact installation structure
Stronger long-term operational reliability
More suitable for high-current systems
In modern new energy and power equipment, high-voltage copper busbars have become an important solution for replacing some traditional wiring harnesses.
Material Advantages: Reconstructing Conductivity and Mechanical Limits at the Grain Scale
| High-purity T2/Y2 copper with extremely low loss matrix | Utilizing high-purity cathode copper through casting and rolling, the content of impurity elements such as oxygen, phosphorus, and iron is strictly controlled. The extremely low impurity grain boundaries not only reduce the volume resistivity to the lower limit of international standards but also eliminate the additional heat generation caused by eddy current losses due to trace magnetic impurities under high voltage and high current. |
| Customized Grain Size and Annealing Toughness | We offer hard (Y2), semi-hard, and soft (M) copper materials to meet different bending requirements. Through precise annealing processes, we control the grain size, ensuring high rigidity (resistance to electrodynamic deformation) in straight sections while imparting excellent ductility to the bending area, eliminating micro-cracks on the outer side and wrinkling on the inner side of the bend. |
| High-temperature strength option for chromium-zirconium copper (CuCr1Zr) | For scenarios involving extreme temperature rise transients, such as UPS systems, chromium-zirconium copper alloy can be selected. BusBar Insulator Manufacturers maintains extremely high yield strength even at 400℃, eliminating the stress relaxation and creep risks of pure copper under high temperature and high current conditions. |
Application Advantages: Covering All Power and New Energy Scenarios
High and Low Voltage Switchgear and Distribution Boxes
Whether it's incoming line cabinets, feeder cabinets, or capacitor compensation cabinets, Copper Ground Bus Bars are a standard configuration for the main circuit. Our galvanized copper busbars have become a standard choice for many complete equipment manufacturers, and their precision and chamfering quality significantly improve assembly efficiency.
Photovoltaic Inverters and Combiner Boxes
In 1500V photovoltaic systems, the DC-side current can reach hundreds of amperes. Bare copper busbars are widely used for DC combiner boxes due to their high conductivity and economy. For outdoor combiner boxes, we recommend nickel-plated copper busbars to resist condensation corrosion from day and night temperature differences.
UPS and Server Power Supplies
In large UPS systems, high-current Distribution BusBars are required to connect the rectifier, inverter, and static bypass. Our flat copper busbars can be routed flush with the inner wall of the chassis without obstructing heat dissipation airflow. For power distribution busbars in server racks, thin nickel-plated copper busbars (2–3 mm thick) are mounted with insulators at the rear of the rack, achieving a high-density power supply.
New Energy Charging Piles and Energy Storage Systems
Rigid copper busbars provide the lowest line impedance and highest reliability between the power modules and charging gun lines of DC charging piles, and between battery clusters and PCS in energy storage containers. Our Positive Bus Bars also support pre-installed NTC temperature sensor mounts for online monitoring of connection point temperatures.
Detailed Display
Surface Roughness Measurement
Profilometry scans showed a surface roughness of Ra = 0.45 μm on the Solid Copper Bus Bar, with no directional tool marks, meeting the requirements for high-voltage electric field uniformity.
Nickel Plating Metallographic Cross-Section
The plating thickness is 3.2 μm, with a clear interface with the copper substrate and no diffusion voids. Porosity testing showed zero micropores penetrating the substrate.
Hot-Dip Zinc Alloy Phase Layer
Under a metallographic microscope, a uniform δ-phase layer (approximately 25 μm) covering the copper substrate is visible. The ζ-phase layer (pure zinc) has a bright surface and is free of zinc slag inclusions.
Corner Rounding Consistency
The radius (R) of the edges of the entire batch of Copper Ground Bus Bars was randomly inspected using an image measuring instrument, with R = 1.2 ± 0.1 mm, ensuring batch stability of the electric field concentration factor.
contact us
We not only provide standardized high-voltage Bus Bar Electric products, but also offer integrated engineering support based on customers' equipment structure, current schemes, and new energy application needs. This support ranges from conductive structure optimization and material and process selection to mass production and delivery, helping projects achieve more stable and efficient long-term operation.
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