Flat Copper Battery Busbar With Heat Shrink Tube
Products Description
These Flat Copper Battery Busbar with Heat Shrink Tubes are manufactured from high-quality copper using precision rolling or stamping processes to create a flat profile. They are encased in high-shrink-ratio, flame-retardant heat-shrink tubing, ensuring complete insulation of the conductor. This rigid connection design provides a low-resistance, high-strength electrical path, while the heat-shrink tubing offers excellent electrical isolation, mechanical protection, and environmental resilience.
Key Product Features:
Highly Conductive Flat Structure: The large-cross-section flat copper busbar minimizes resistance and heat generation, supporting high continuous current transmission.
Reliable Heat-Shrink Insulation: The heat-shrink tubing conforms tightly to the busbar surface, creating a uniform, void-free insulating layer.
Rigid Connection Stability: The rigid copper busbar ensures precise positioning, low contact resistance, and long-term stability.
Comprehensive Protection: The heat-shrink tubing is flame-retardant, abrasion-resistant, oil-resistant, and moisture-proof, making it suitable for the demanding conditions of battery compartments.
Key Application Scenarios
New Energy Vehicles (EV/HEV)
Rigid busbars connecting battery modules within traction battery packs, and internal connections between the BDU (Battery Distribution Unit) and the high-voltage PDU (Power Distribution Unit).
Energy Storage Systems (ESS)
High-voltage power distribution busbars for the main circuits of containerized energy storage cabinets and battery racks.
Industrial High-Power Power Supplies and Inverters
Main circuits within UPS (Uninterruptible Power Supply) units, high-power variable frequency drives (VFDs), and grid-tied PV inverters.
Rail Transit and DC Power Distribution
Onboard high-voltage electrical enclosures and industrial high-voltage DC control cabinets.
Detail Showcase: Quality Indicators from an Engineering Perspective
Heat-shrink tubing fit
In high-quality products, the heat-shrink tubing conforms perfectly to the copper busbar surface, free of air bubbles, wrinkles, or delamination. Pressing with a finger should reveal no gaps between the tubing and the Insulated Heat-Shrinkable Copper Bars.
01
Insulation extension at ends
The extension of the heat-shrink tubing beyond the ends of the Heat Shrinkable Busbar Insulating Tape is uniform and consistent, with no misalignment or damage. This extension is a critical feature for providing adequate creepage distance.
02
Insulation integrity at bends
The heat-shrink tubing at bends transitions smoothly without bunching, thinning due to stretching, or cracking. Bends are the areas where insulation is most susceptible to damage.
03
Surface finish consistency
The plating on the Copper Busbar with Heat Shrink Tube Insulation surface (including terminal contact areas) is uniform, with no peeling or oxidation. The boundary between the covered and uncovered sections is distinct and neat.
04
Color uniformity
The color of the heat-shrink tubing is consistent (especially for the orange high-voltage warning color), with no color variation or fading. Uneven color may indicate material or process issues.
05
In-depth analysis of technical features: microscopic guarantee of electrical safety
High dielectric strength and creepage distance
By selecting highly flame-retardant heat-shrinkable materials, the insulation voltage of the product can reach the kV level, fully meeting the insulation requirements of the high-voltage system of new energy vehicles. The design strictly controls the creepage distance and electrical clearance to ensure that surface flashover does not occur in humid and salt spray environments.
Environmental aging resistance
The battery pack will experience temperature shocks from extreme cold to extreme heat throughout its life cycle. Our heat-shrinkable tubing has been cross-linked and radiated, and has a stable molecular structure. It will not be embrittled or cracked in a high-temperature environment for a long time, and its service life is the same as that of the entire vehicle.
Anti-vibration wear
There may be a risk of friction between the hard busbar and the surrounding structural parts. Heat shrink tubing acts as a layer of "soft armor" and provides excellent wear protection. Even if the Pure Solid Copper Busbar with Heat Shrink Tubing vibrates slightly, the bushing is in contact with the structural parts, avoiding the risk of a short circuit caused by wear of the copper bar body.
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The Copper Busbar Connector with Insulated Heat Shrink Tube integrates copper conductors, highly reliable insulation, and precision manufacturing to meet the comprehensive requirements of new energy battery systems for efficient conductivity, safe insulation, and space optimization.
Leveraging stable material properties, mature manufacturing capabilities, and extensive experience in engineering customization, this product helps customers in the new energy vehicle, battery energy storage, and industrial power equipment sectors enhance system reliability, optimize product design, and reduce long-term operational and maintenance risks.
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