Copper Busbar With Heat Shrink Tube Insulation
Products Description
A Copper Busbar with Heat Shrink Tube Insulation is, in essence, a precision-machined copper conductor component featuring protective insulation.
The product utilizes the copper busbar to handle primary current transmission. At the same time, the heat-shrink tubing provides electrical isolation and mechanical protection, resulting in a component that combines high electrical conductivity with safe insulation capabilities.
Its key features include:
1. Efficient Current Transmission
Constructed using high-quality copper as the conductive core, the material offers excellent conductivity and stable electrical performance, effectively minimizing resistive losses at connection points and enhancing energy transmission efficiency.
2. Integrated Insulation Design
Upon heating, the heat-shrink tubing contracts to tightly encase the copper busbar, creating a continuous insulating layer that mitigates safety risks associated with exposed conductors.
Manufacturing Process: End-to-End Control from Precision Cutting to Intelligent Heat Treatment
Copper Busbar Pre-treatment
After precision cutting and punching, the Heat Shrinkable Busbar Insulating Tapes enter a fully automated degreasing and cleaning line. Removing surface oils and oxide layers is a critical step to ensure strong adhesion of the hot-melt adhesive.
Pre-heating and Sleeving
This is pre-heated based on its thickness and the ambient temperature, followed by the application of pre-cut heat-shrink tubing in a clean environment.
Graduated Heating and Shrinkage
This is the core of the process. We utilize tunnel-type infrared ovens or electromagnetic induction heating equipment for heat treatment.
Cooling, Setting, and Quality Inspection
Upon completion of shrinkage, the Heat Shrink Tube Copper Busbar Connection enters a constant-temperature cooling zone to ensure the hot-melt adhesive fully cures and forms a microscopic interlocking structure.
Application Advantages: A Versatile Electrical Backbone
| Energy Storage Systems (ESS) | Used between battery modules and between battery clusters and combiner cabinets, rigid busbar connections with insulating sleeves withstand the stresses of high-current charging and discharging; the insulation layer effectively prevents short-circuit risks caused by battery leakage, thereby enhancing the safety of the battery pack. |
| Low-Voltage Switchgear (e.g., MNS, GCK) | Serving as main or branch, rigid connections simplify internal assembly and reduce phase-to-phase spacing, enabling the distribution cabinet to deliver higher rated current outputs within a more compact footprint. |
| Industrial Variable Frequency Drives (VFDs) and Servo Drives | In the DC bus section, rigid busbars provide robust support for capacitor banks and ensure extremely low contact impedance, guaranteeing stable equipment operation even within demanding industrial power grid environments. |
| New Energy Vehicle (NEV) Charging Piles | Designed for the compact internal architecture of high-power fast-charging piles, heat-shrink insulated busbars ensure clear isolation between high-voltage/high-current power circuits and low-voltage control circuits, enhancing electrical safety in high-frequency, high-current operating environments. |
Detailed Features
Uniform insulation coating
Upon heat shrinking, the tubing forms a smooth, even insulation layer over the Copper Flat Square Busbars with PVC Heat-Shrink surface, free from bubbles, wrinkles, or delamination. The insulation fully encapsulates the busbar's edges and corners, leaving no gaps or weak points.
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Neat end termination
The tubing terminates cleanly at the edge of the connection terminal, resulting in a flush, burr-free end face. A precise safety clearance is maintained between the insulation end and the edge of the contact surface, ensuring insulation integrity without compromising the tightness of the bolted connection.
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Clear polarity markings
Polarity symbols (+/-), phase identifiers (L1/L2/L3), voltage ratings, product codes, and other information can be printed on the tubing surface as required, facilitating identification during on-site installation and subsequent maintenance.
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Precision terminal machining
Connection holes on the Heat Shrink Sleeve Insulated Copper Busbar contact surfaces are precision-drilled and deburred, with diameters and spacing machined strictly according to customer drawings. Contact surfaces are tin-plated or silver-plated to ensure a smooth, flat finish that minimizes contact resistance.
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contact us
If you are selecting components for projects involving new energy vehicles, energy storage systems, or industrial power distribution equipment, we can provide Heat Shrink Tube Insulation Copper Busbar solutions tailored to your structural design, current requirements, and installation environment, leveraging our professional manufacturing capabilities to ensure reliable project delivery and long-term, stable operation.
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