Copper Busbar Connector With Insulated Heat Shrink Tube
What is a Copper Busbar Connector with Insulated Heat Shrink Tube?
Copper Busbar Connector with Insulated Heat Shrink Tube featuring insulated heat-shrink tubing is essentially a flexible or semi-rigid power connection component. The conductive element utilizes multi-layer or solid high-purity copper to ensure low electrical resistance and efficient heat dissipation, while the insulation consists of radiation-crosslinked polyolefin or EVA heat-shrink tubing; upon heating, this material conforms tightly to the copper busbar surface, creating a uniform, void-free insulating layer.
These connectors are distinguished by three key characteristics: first, their "shrink-memory" property ensures the insulation closely matches the busbar's profile, maintaining a tight fit even over bends or localized protrusions; second, the insulation provides both electrical isolation and physical protection, guarding against moisture, dust, minor mechanical impacts, and chemical corrosion; third, the overall structure can be configured-as rigid straight bars, flexible laminated stacks, or custom irregular shapes-to balance current-carrying capacity with spatial constraints.
This composite design makes the product suitable for a wide range of applications, from rigid busbar arrangements in switchgear to internal connections in battery packs that require vibration and thermal expansion absorption, thereby delivering true engineering versatility.
Technical Features and Key Functions for PVC Heat Shrinkable Sleeves For Busbar
Primary Function
Establishes reliable current-carrying connections between busbars, or between busbars and components, while providing durable insulation protection.
Additional Functions
Moisture-proof sealing, resistance to salt-spray corrosion, phase-color identification, and mechanical protection against impact and abrasion.
Technical Highlights
A gap-free interface fit minimizes the risk of partial discharge; a sealant layer blocks corrosion paths where moisture might otherwise creep along the copper busbar; and a pre-formed design allows for on-site assembly using only standard fastening tools-eliminating the need for hot work and ensuring compliance with the HSE (Health, Safety, and Environment) regulations of many client sites.
Adaptability Across Diverse Applications for Insulated Flexible Busbar With PVC Insulation
Products can be customized to meet the specific requirements of various industries:
New Energy Sector
For high-voltage DC applications involving energy storage battery packs and PV inverters, modified polyolefin heat-shrink tubing (rated for 150°C) is available to accommodate voltages up to DC 1000V. High-visibility orange options are provided to comply with safety labeling standards for high-voltage new energy systems.
Industrial Control Sector
For environments containing corrosive gases-such as in metallurgy or chemical processing-anti-corrosion coatings can be applied to the heat-shrink tubing, and busbars can be nickel-plated. These measures enhance resistance to salt spray, acids, and alkalis, ensuring a service life of over 20 years.
Rail Transit Sector
Products are certified to EN45545 fire safety standards; their low-smoke, halogen-free properties minimize toxic emissions during a fire, thereby safeguarding personnel evacuation. They also offer vibration and impact resistance to withstand the dynamic operating conditions of trains.
Customization Services
We support the production of custom-shaped busbar connectors based on customer drawings. Our comprehensive processing capabilities-including stamping, bending, punching, plating, and heat-shrink insulation application-allow for ready-to-install delivery, thereby reducing on-site processing time for the customer.
Frequently Asked Questions for Insulated Heat-Shrinkable Copper Bars
1. What materials can be used for copper busbar connectors?
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Common materials include T2 copper, C11000, and Cu-ETP; materials can also be selected based on customer specifications, conductivity requirements, and processing needs.
2. Can copper busbar connectors be customized according to drawings?
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Yes. Products can be customized based on 2D drawings, 3D CAD files, or physical samples, covering parameters such as length, width, thickness, hole positioning, bending angles, and insulated areas.
3. What type of heat-shrink tubing is suitable for copper busbars?
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Suitable heat-shrink insulation materials can be selected based on the operating environment, electrical requirements, mechanical protection needs, and temperature conditions. Heat-shrink tubing for busbar insulation may reference standards such as IEC 60684-3-283, though the final material and structure should be confirmed based on the specific application.
4. Can the copper busbar be tin-plated before heat-shrinking?
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Yes. Depending on the application environment and connection requirements, the copper busbar can undergo surface treatments-such as tin plating-before heat-shrink insulation. The surface treatment method is determined by considering the connection type, environmental corrosion conditions, and subsequent assembly processes.
5. What information is required for a customized busbar connector?
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It is recommended to provide product drawings, copper material grade, busbar dimensions, mounting hole details, bending configuration, operating environment, insulation requirements, and estimated purchase quantity. If complete drawings are not yet available, samples or equipment interface details can be provided for our engineering team to verify the structural design.
contact us
To address complex electrical topologies and specific operational requirements, we do not offer off-the-shelf products; instead, leveraging our extensive expertise in tooling development and high-voltage electrical connection manufacturing, we provide global engineering clients with customized Customized Heat Shrink Tubes Copper Busbar connection system solutions that combine high reliability with cost-competitiveness.
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