Dip Insulated Busbar
Products Description
Dip Insulated Busbars are critical components used in high and low-voltage electrical systems for power conduction and distribution. They are created by uniformly dipping a copper or aluminum busbar in plastic (Dip Coating), forming a dense insulating protective layer on the surface of the metal conductor.
This coating not only provides excellent insulation and corrosion resistance but also effectively prevents external factors such as dust, moisture, and chemicals from corroding the conductor, ensuring safe, stable electrical connections and reliable operation.
This product is widely used in new energy storage systems, industrial control cabinets, distribution boxes, inverters, charging piles, power equipment, rail transportation, and communication cabinets, and is an important component for achieving lightweight, modular, and safe systems.
Product Features and Performance Advantages
1. Excellent Insulation and Protection Performance
The PVC Dipping Insulated Busbar is uniformly coated with high-temperature liquid PVC or PE insulation material using a single copper or aluminum busbar, resulting in a consistent coating thickness and strong adhesion.
Compared to traditional heat-shrink tubing or spraying methods, the dip-coating process ensures:
Complete Coverage: Seamless, bubble-free, and no exposed areas;
High Insulation Strength: Dielectric strength up to 20kV/mm or higher;
Moisture and Corrosion Resistance: Effectively blocks moisture, salt spray, and oil contamination;
Stable High and Low Temperature Performance: Long-term operating temperature range of -40°C to 120°C.
This allows the product to maintain stable electrical performance even in complex environments, making it suitable for harsh applications such as outdoor use, high humidity, or high dust levels.
2. Stable conductivity and lower losses
The PVC Coated Bus Bars conductors are manufactured using high-quality oxygen-free copper (T2) or high-conductivity aluminum (1060/6061). The surface undergoes precision grinding and cleaning, followed by dip-coating to ensure:
The conductor cross-section is free of oxidation and impurities.
Low resistivity and strong current-carrying capacity;
Low overall temperature rise and high energy transfer efficiency.
Through scientifically designed cross-sectional dimensions and layout, the PVC Dipped Laminated Flexible Copper maintains extremely low power loss under high current conditions, ensuring energy saving and long-term operation of the system.
Detailed Display and Manufacturing Highlights
Uniform insulation thickness and rounded edges: Prevents sharp corner penetration;
Pre-machined exposed areas or screw holes at the ends: Facilitates connection;
Color-coded visual identification: Enhances assembly safety;
Anti-slip coating option: Improves manual operation safety.
Multi-layer busbar stacking structure optional: Adapts to different current ratings.
Each Plastic Dipping Copper Busbar undergoes precise grinding and automated testing to ensure the final product meets triple standards of mechanical strength, electrical performance, and visual quality.
Application Areas and Value Extension
| Energy Storage Systems (ESS) |
Battery module and system, Plastic Dipping Copper Busbar connection Improving system safety, preventing short circuits, and leakage Suitable for outdoor containerized energy storage and commercial energy storage cabinets |
| Electric Vehicles and Charging Facilities |
DC Insulated Custom Copper Bus Bar with PVC Dipping connection, ensuring stable high-current conduction High-temperature and arc-resistant insulation layer ensures system safety |
| Industrial Power Distribution and Control Systems |
Core electrical connectors for PLC control cabinets, inverter cabinets, distribution boxes, etc. Improving the simplicity of electrical wiring and system reliability |
| Rail Transit and Wind Power Systems |
Maintaining stable electrical contact and insulation protection in high-vibration environments Suitable for high-altitude, high-humidity, and highly corrosive environments |
| Communication and Data Center Power Distribution | Compact structure and aesthetically pleasing design meet high-density power distribution requirements |
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