Epoxy Coated Copper Battery Bus Bar For Electric Bus
Products Description
As the requirements for safety, stability, and high current carrying capacity in electric bus energy systems continue to increase, the design of battery connection systems is being comprehensively upgraded from traditional bare copper busbars to composite structures with "high insulation, high withstand voltage, and high reliability."
Epoxy Coated Copper Battery Bus bar for Electric Bus use T2/TU1 high-conductivity copper as the base material, with the surface integrally coated using arc-resistant epoxy powder. Through the protection of a high-insulation, high-heat-resistant, and strongly adhesive coating, both current-carrying performance and structural insulation are improved, making it a key current transmission component in the electric bus battery pack and power architecture.
This product is specifically designed for new energy buses, large pure electric buses, and fast-battery swapping buses. It is suitable for harsh operating conditions involving high current, high vibration, and high temperature, comprehensively improving the system's safety level and operational reliability.
Core Functions: Meets the core requirements of electric bus battery systems
High-Power Stable Transmission
High-purity Epoxy Powder Coating Insulated Busbars and optimised cross-section design ensure stable transmission of high currents from 200A to 3000A, with voltage fluctuations ≤ ±2%. This meets the power demands of electric buses during startup, acceleration, and hill climbing, preventing power attenuation due to unstable power supply.
01
Extreme Environment Protection
The epoxy coating's anti-corrosion, moisture-proof, wear-resistant, and vibration-resistant properties make it suitable for outdoor parking, complex road conditions, and frequent maintenance scenarios for electric buses. It resists multiple forms of corrosion from dust, rain, salt spray, and vibration, ensuring long-term stable operation of the power system.
02
Long-Term Maintenance-Free Operation
The ageing-resistant and corrosion-resistant coating design and vibration-resistant, anti-loosening connection structure reduce epoxy powder coated busbar insulation failures and maintenance frequency, adapting to the 8-year/500,000-kilometre operating cycle of electric buses, reducing the overall operating costs for bus companies and operators.
03
Thermal Management Co-optimisation
Excellent heat dissipation performance and temperature rise control prevent battery system performance degradation caused by localised heat accumulation, delay cell ageing, and improve the driving range and battery cycle life of electric buses.
04
Comprehensive Safety Protection
Flame-retardant insulation, short-circuit protection, puncture resistance, and anti-loosening design, combined with automotive-grade safety certification, provide multiple safety redundancies for the high-voltage power distribution system of electric buses, reducing the risks of fire, leakage, and other hazards, and ensuring the safety of passengers.
05
Precision Manufacturing Process: Engineering Control from Materials to Finished Product
Pre-treatment Process
Nanoscale cleaning and activation treatment of the busbar coating surface ensures a perfect bond between the epoxy coating and the copper substrate.
Intelligent Coating Control
Utilising electrostatic fluidised bed spraying technology, we precisely control coating thickness and uniformity, avoiding the unevenness issues of traditional spraying.
Temperature Gradient Curing
Staged temperature control achieves perfect curing of the epoxy resin, ensuring minimal stress on the coating and Insulated coating Tinned solid Copper Busbar Connector.
End-to-End Quality Inspection
Each batch of Copper Busbars with Epoxy Powder Insulations undergoes insulation resistance, withstand voltage, thermal cycling, and vibration testing to ensure engineering-grade consistency.
Application Advantages: Epoxy-coated copper battery busbars are the cornerstone of ensuring the safety of the high-voltage system in electric buses
Internal Series Connection within Battery Modules
Epoxy Powder Coating Insulated Busbar Connecting high-current paths between battery modules, its compact and robust characteristics are perfectly suited to the limited space within the modules.
Battery Pack Main Circuit
As the main positive and negative busbars from the battery pack output to the high-voltage distribution box (PDU), they carry the largest current of the entire vehicle, making their safety crucial.
Internal Space of the High-Voltage Distribution Box (PDU)
Connecting critical components such as relays and fuses within the PDU, their flame-retardant and insulation properties are a key aspect of the overall vehicle safety design.
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