Dip Insulated Busbars
Products Description
The PVC Dipped Copper Busbar is a high-current conductive component designed for insulated power transmission inside EV battery systems, power distribution units (PDU), inverter assemblies, and industrial electrical equipment.
Unlike traditional bare copper bars or wrapped insulation structures, this insulated copper busbar integrates the conductive copper substrate and molded PVC insulation layer into a unified assembly structure. The insulation coating fully covers the conductor surface while reserving designated electrical connection areas for bolted or welded installation.
This product is commonly used in:
Electric vehicle battery packs
Energy storage cabinets
High-voltage PDU systems
DC power distribution equipment
Industrial inverter systems
Charging infrastructure
Electrical relay components and busbar transition structures
Material Advantages: Microscopic Defense System of Modified Polymer Powders
The performance of the insulating coating determines the environmental adaptability of the PVC Dipping Insulated Busbar. We have carefully selected multiple high-performance engineering plastic powders and deeply modified them for new energy applications.
1. Hybrid Modification Technology of Epoxy Resin and Polyethylene:
Superior Dielectric Properties: We use modified epoxy powder or polyethylene blends, which possess extremely high volume resistivity and dielectric strength. Under the high-voltage platforms of 800V or even 1000V in new energy vehicles, a thin coating can withstand stringent voltage tests, significantly reducing the phase-to-phase distance requirements and saving valuable space within the battery pack.
Chemical Stability and Corrosion Resistance: The modified material possesses excellent resistance to acids and alkalis, salt spray, and coolant. For potential electrolyte leakage or extreme humid and hot environments in power battery packs, the coating can construct an inert chemical barrier, preventing electrical performance degradation caused by copper substrate corrosion.
2. Halogen-free flame retardancy and environmental friendliness: Strictly adhering to RoHS and REACH standards, the dip-coating materials we select are free of heavy metals and harmful halogens. The materials possess self-extinguishing flame-retardant properties (meeting UL94 V-0 standards), effectively preventing flame spread in the event of an electrical fire hazard. Furthermore, they produce low smoke and are non-toxic during combustion, meeting the stringent safety regulations for interior materials in new energy vehicles.
Production Process
Raw Material Selection and Inspection
High-purity copper or aluminum materials are selected, and their conductivity is tested for PVC Dipped Insulated Bus Bar.
01
Busbar Stamping and Forming
The required structure is formed through stamping, shearing, and bending.
02
Surface Treatment
This includes cleaning, degreasing, and necessary surface treatments to improve dip coating adhesion.
03
Dip Coating Insulation Treatment
Dip coating is performed in a temperature-controlled environment to ensure uniform insulation coverage.
04
Cooling and Curing
A stable insulation layer structure is formed for the Plastic Dipping Copper Busbar.
05
Application Advantages: Reliable Verification in Multiple Scenarios
| New Energy Vehicle Battery Modules | Used for series connection between cells; the dip-coated insulation layer prevents short circuits between adjacent Plastic Dipping Copper Busbars; orange markings comply with high-voltage safety standards. |
| BDU/PDU High-Voltage Distribution Boxes | Connects relays, fuses, and current sensors to irregularly shaped Dipping Busbar for Connections, achieving complex topologies within a compact space. |
| OBC On-Board Chargers | In high-frequency switching scenarios, the low dielectric constant of the dip-coated layer reduces parasitic capacitance and electromagnetic interference. |
| Photovoltaic Inverters | Outdoor scenarios require weather resistance, UV resistance, and water vapor resistance; the epoxy dip-coated solution passes dual 85°C damp heat tests. |
| Energy Storage Systems | Internal connections within high-voltage boxes; partial discharge suppression is crucial at 1500V voltage levels. |
| Industrial Frequency Inverters | Under high current and high vibration conditions, the adhesion of the dip-coated layer has withstood long-term testing. |
FAQ
What is a PVC-dipped copper busbar?
A PVC-dipped copper busbar is a conductive copper busbar coated with an integrated PVC insulation layer for electrical isolation and mechanical protection.
Why is PVC dipping used instead of insulation tape?
PVC dipping creates a continuous insulation layer around complex conductor shapes, reducing edge exposure and improving long-term insulation stability.
Can the exposed terminal areas be customized?
Yes. The exposed conductive areas, hole positions, and insulation boundaries can be customized according to assembly requirements.
Which applications commonly use insulated copper busbars?
Common applications include EV battery systems, energy storage cabinets, power distribution units, industrial electrical equipment, and high-current DC systems.
contact us
For engineering procurement and equipment manufacturers, selecting the right busbar products not only affects equipment performance but also directly impacts the long-term reliability of the project.
We offer not only standardized products but also customized dip-insulated busbar solutions based on our clients' equipment structure, installation space, and current requirements. This helps optimize electrical connection design and improve overall system stability.
If you are looking for a reliable PVC Dipped Laminated Flexible Copper supplier, please send an inquiry to our engineering team. We will provide professional busbar structure and manufacturing solutions based on your application needs.
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