Custom Solid Power Bus Bar With Insulated Dipping Tube
What is a Custom Solid Power Bus Bar with Insulated Dipping Tube?
This Custom Solid Power Bus Bar with Insulated Dipping Tube is a rigid, solid-conductor power distribution assembly. It uses a solid copper bar (or aluminum bar) with high conductivity as the base, and uses a special fluid impregnation process to coat the surface of the conductor with a uniform, dense, and insulating resin layer with a certain thickness.
Different from traditional busbars: Traditional heat-shrinkable tube busbars are prone to stress concentration at the bends, leading to pipe wall rupture or thinning of the insulation layer; while the dip-molding process achieves a "molecular-level" fit between the insulation layer and the copper bar. No matter how complex the geometry is, the thickness of the insulation layer always remains uniform.
Application positioning: Mainly used in high-voltage power distribution scenarios where the space structure is relatively fixed, the insulation protection level is extremely high, and must withstand certain mechanical stress, such as the connection between EV battery pack modules, PDU high-voltage distribution unit, photovoltaic combiner box main circuit, etc.
Key Functions: Integration of power transmission and safety isolation for Pure Copper Insulated BusBar
High-current, low-impedance transmission
The solid copper body provides the shortest resistive path from input to output, minimizing conduction losses in power devices (IGBTs/SiC MOSFETs).
High-voltage safety isolation
The dip-coated insulation layer provides electrical isolation between the conductor and surrounding metal structures (such as housings, heat sinks, or adjacent busbars), preventing short circuits and electric shock hazards.
Mechanical protection
The dip-coated layer serves as a protective coating against corrosion and wear, preventing copper surface oxidation, scratches, or chemical corrosion.
Structural support
The rigidity of the solid busbar allows it to function as a structural component within the system, supporting power modules or capacitor banks and simplifying system assembly.
Manufacturing Process: A Precision Journey from Furnace to Finished Insulated Flat Copper Busbar
Our production process integrates the best practices of metalworking and polymer material processing:
Precision Cutting and Forming
Materials are cut to specific lengths using high-precision saws or CNC lathes, followed by 3D forming on large-scale CNC bending machines. Spring-back is strictly controlled during the bending process to ensure angular accuracy.
01
Surface Cleaning and Pre-treatment
This stage is critical to the quality of the plastic coating. Workpieces pass through an automated pre-treatment line involving degreasing, pickling, rinsing, surface conditioning, phosphating, and drying. This ensures the surface is free of oil and oxide scale while forming a dense phosphate crystal layer.
02
Pre-heating
The treated metal workpieces are heated to the specific temperature required for powder melting (typically between 200°C and 300°C). Uniform temperature control directly determines the final quality of the coating.
03
Fluidized Bed Coating
The pre-heated workpieces are immersed in a fluidized bed. Airflow suspends the plastic powder, creating a boiling-like state; upon contact with the hot workpiece, the powder instantly melts and adheres to the surface, forming a uniform plasticized layer.
04
Plasticization and Curing
After coating, the workpieces enter a curing oven and are held at a controlled temperature for a specific duration. This allows the coating to fully cross-link and cure, achieving optimal physical and mechanical properties.
05
Frequently Asked Questions
Q1: What applications are insulated dipping tube busbars mainly used for?
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Power busbars featuring insulated dipping tubes are primarily used in new energy vehicles, high-voltage energy storage systems, photovoltaic inverters, charging equipment, and industrial power distribution systems to ensure safe, high-current connections.
Q2: Can the solid power busbar be customized according to our drawings?
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Yes. Apollo supports material selection, structural design, manufacturing, and sample validation based on customer 2D/3D drawings, meeting specific spatial and installation requirements for various types of equipment.
Q3: What insulation materials can be used for dipped insulated busbars?
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Depending on the application environment, options include PVC, thermoplastic materials, and high-performance flame-retardant insulation materials to meet specific temperature, voltage, and weather-resistance requirements.
Q4: What is the difference between an insulated busbar and a traditional cable connection?
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Compared to traditional cables, insulated busbars offer advantages such as a fixed structure, high space utilization, stable current transmission, and efficient assembly, making them better suited for the compact internal designs of new energy equipment.
Q5: Can Apollo support mass production after prototype approval?
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Yes. Apollo possesses a comprehensive manufacturing process-spanning engineering assessment, prototype development, and small-batch validation through to full-scale production-capable of meeting the long-term supply needs of new energy customers.
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If you are developing high-voltage electrical connection solutions for new energy vehicles, photovoltaic, or energy storage projects, Apollo can provide professional busbar design, material matching, and manufacturing support tailored to your system requirements, helping you achieve reliable and highly consistent engineering connection solutions.
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