Copper Busbars With Epoxy Powder Insulation
Products Description
Copper Busbars with Epoxy Powder Insulations are electrical connection units that use high-conductivity electrolytic copper as the base material and insulate the entire busbar surface with high-adhesion epoxy powder.
Compared to traditional heat-shrink tubing and PVC conduit insulation, epoxy powder coating offers more uniformity, higher mechanical strength, and superior ageing resistance, significantly improving system safety and operational stability.
It is widely used in:
Energy Storage Battery Systems (ESS)
Photovoltaic Inverters / PCS
Electric Drive Systems for New Energy Vehicles
Industrial Distribution Cabinets / Substation Equipment
High-Power UPS Systems
High-Voltage Electrical Equipment and Epoxy Powder Coating Insulated Busbar Connection Systems
Technical Features: Core process breakthroughs, balancing performance and reliability
Insulation and Conductivity Synergistic Technology
Through microscopic roughening treatment of the copper surface (roughness Ra=1.2-1.5μm), the epoxy powder coating forms a dual adhesion of "physical bonding + chemical bonding" with the copper material. Insulation resistance ≥10¹²Ω, breakdown voltage ≥35kV/mm, eliminating leakage risks in high-voltage scenarios while not affecting the original conductivity of the copper material.
Environmental Adaptive Technology
The coating incorporates weather-resistant modifiers, demonstrating no corrosion or insulation degradation after 1000 hours of continuous testing in harsh environments with 95% humidity and 5% salt spray concentration. For high-temperature scenarios, optimised curing process parameters increase the coating's heat distortion temperature to 150℃, making busbar coating suitable for high-temperature operating environments such as new energy storage, metallurgy, and chemical industries.
Low-loss transmission technology
The epoxy powder coated busbar insulation adopts an optimised rectangular cross-section design, reducing the skin effect and resulting in more uniform current distribution. Compared with traditional copper busbars, the current carrying capacity is increased by 10%-15%, and long-term operating energy consumption is reduced by 8%-10%, meeting the energy-saving requirements of engineering projects.
Design Advantages
| High Customization | Our design team collaborates closely with your engineers, co-designing based on your 3D models. Whether it's complex branching structures, integrated terminal blocks, or pre-drilled holes in specific locations, we can achieve precise implementation. |
| Integrated Design | We can directly integrate sensor mounting positions, grounding indicators, colour-coded markings, and other functions into the Insulated coating Tinned solid Copper Busbar Connector, making it a more feature-rich intelligent component and helping your equipment upgrade towards intelligence and modularity. |
| Aesthetics and Marking | We offer a variety of epoxy powder colours (such as red, yellow, green, blue, and black), which not only meet international standards for phase sequence marking but also enhance the aesthetics and professional image of your products. |
Application Scenarios: Empowering Power Upgrades Across Multiple Industries
1. Industrial Power Distribution Systems
* Automobile Manufacturing Plants: Used for power supply lines to robots in welding workshops, resistant to welding spatter and oil erosion, ensuring 24-hour continuous production;
* Steel Smelting Plants: Stable operation in high-temperature (80℃+) and dusty environments, replacing traditional cable trays and reducing maintenance frequency.
2. New Energy Sector
* Photovoltaic Inverter Cabinets: Compact structure adaptable to outdoor cabinet space limitations, resistant to UV ageing (passed 1000-hour xenon lamp aging test);
* Energy Storage Power Stations: High-current connection between battery clusters, low impedance characteristics reduce energy loss, and improve system charging and discharging efficiency.
3. Commercial Buildings and Infrastructure
* High-Rise Buildings: Vertical cabling within shafts, fire resistance meeting GB50016 fire protection standards, replacing dense Epoxy Coated Copper Battery Bus bar for Electric Bus trunking;
* Rail Transit: High-current transmission in subway traction substations, vibration resistance certified to EN 50155 railway standards.
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