Insulated Busbar
Product Types and Structural Features
Laminated Busbar
This product utilizes multiple layers of conductive copper tape laminated together, with insulating dielectric interlayers heat-pressed to achieve low inductance and high-density wiring.
Features:
Using international standard conductive copper materials: GB: T2Y2, DIN: E-Cu58, EN: Cu-ETP, ISO: Cu-ETP, UNS: C11000, JIS: C1100, BS: C101;
Copper purity ≥99.99%, conductivity ≥97% IACS;
Hardness 80-110 HV, tensile strength 245-345 MPa;
Excellent conductivity, extremely low voltage drop, and strong electromagnetic interference resistance;
Widely used in power electronic modules and energy storage system main busbars.
Epoxy Powder Coated Busbar
The busbar surface is electrostatically sprayed with epoxy powder, forming a dense insulation layer that is wear-resistant, moisture-proof, and withstands high voltage.
Features:
Common colors: red, orange, blue, green, black;
Flame retardant rating: UL94-V0;
Operating temperature: -45°C to +150°C;
Suitable for high-voltage busbars, energy storage compartments, and charging systems.
PVC-Dipping Insulated Busbar
Using a hot-dip process, the PVC layer is evenly coated on the copper surface, resulting in a smooth appearance and a smooth touch.
Features:
Common colors: red, orange, blue, green, black;
The insulation layer adheres firmly, resists corrosion and vibration, and is suitable for protecting busbars with complex curved structures and long busbars.
PET Insulated Busbar for Film Capacitors
This series is designed specifically for film capacitors and high-frequency circuits in new energy vehicles, featuring a laminated PET insulating paper structure.
Features:
Insulation materials are made from GTS (USA) and KREMPEL (Germany), available in white or creamy white.
Excellent dielectric strength and heat resistance.
Suitable for EV capacitor modules, DC-Link busbars, and onboard power distribution systems.
Materials and Process Parameters
| Project | Laminated Busbar | Powder-Coated Insulated Busbar | Plastic-Dip Insulated Busbar | PET-Insulated Busbar (for Film Capacitors) |
| Base Material Standards | GB/T2Y2, DIN E-Cu58, EN Cu-ETP, etc. | Same as above | Same as above | Same as above |
| Copper Purity | ≥99.99% | ≥99.99% | ≥99.99% | ≥99.99% |
| Conductivity | ≥97% IACS | ≥97% IACS | ≥97% IACS | ≥97% IACS |
| Hardness/Tensile Strength | 80–110 HV / 245–345 MPa | Same as above | Same as above | Same as above |
| Surface Treatment | Silver/Tin/Nickel Plating, Thickness: 3–12 μm | Same as above, Surface Pre-treatment: Spraying | Same as above, Surface Pre-treatment: Plastic-Dip | Same as above, PET Pre-treatment: Lamination |
| Insulation | PET/PVC/Epoxy/PE Multilayer Lamination | Epoxy Powder Coating | PVC Dipping | PET insulation paper laminate |
| Flame-retardant rating | UL94-V0 | UL94-V0 | UL94-V0 | UL94-V0 |
| Operating temperature | -45°C to +150°C | -45°C to +150°C | -45°C to +150°C | -45°C to +150°C |
| Resistance | ≤0.00001Ω | ≤0.00001Ω | ≤0.00001Ω | ≤0.00001Ω |
| Withstand voltage | 3500–5000 VDC | 3500–5000 VDC | 3500–5000 VDC | 3500–5000 VDC |
| Current carrying capacity | 100–2000A | 100–2000A | 100–2000A | 100–2000A |
| Assembly fasteners | US PEM stainless steel nuts, studs, spacers, and screws | Same as left | Same as left | Same as left |
| Monthly production capacity | 50,000,000 pcs | Same as left | Same as left | Same as left |
| Certification standards | ISO9001, IATF16949, RoHS, REACH | Same as left | Same as left | Same as left |
Manufacturing Capabilities and Process Control
XIAMEN APOLLO boasts advanced copper busbar stamping, bending, welding, and surface treatment production lines, combined with automated coating and constant temperature curing equipment, enabling highly consistent mass production.
Mass Order Manufacturing Process:
Copper strip slitting → Progressive die stamping → Surface coating → Insulation coating → Heat curing → Assembly and testing.
Sample or small order manufacturing process:
Copper sheet shearing → Laser cutting → CNC punching and bending → Surface coating → Insulation coating → Heat curing → Assembly and testing
Quality Assurance System:
Full inspection of resistance, voltage withstand, and insulation temperature resistance;
3D dimensional measurement and thickness testing;
Insulation adhesion and impact testing;
Conductivity, thermal cycling, salt spray testing, and other reliability verifications.
Delivery and Service Parameters
| Item | Description |
| Free Samples | 1–10 free samples available |
| Lead Time | 10–20 days for samples (including mold development), 7–10 days for orders |
| Packing | Inner EPE foam/blister pack, outer carton + pallet |
| Payment Terms | T/T, L/C, accepting USD/EUR/RMB settlement |
| OEM/ODM | services available based on customer drawings and specifications |
| Operating Range | -45°C to 150°C, withstanding transient shocks and high-voltage loads |
Typical Applications
Film capacitors for new energy electric vehicles and hybrid vehicles
New energy battery packs and high-voltage distribution busbar systems
Photovoltaic inverters and energy storage system DC busbars
Industrial distribution cabinets and power control equipment
Rail transit power conversion devices
Cloud server UPS systems
Technical Support and Customization Services
We provide one-stop technical services, from electrical design verification, insulation material selection, thermal simulation optimization, to rapid prototyping.
Customizable features include:
Copper busbar size, thickness, and bend angle;
Insulation colour and coating method;
Plating thickness and corrosion resistance level;
Terminal assembly and connection structure design.
Our engineering team can provide structural evaluation and manufacturing feasibility analysis based on CAD/STEP/PDF files to ensure product compatibility with your application standards and certification systems.
Reasons to Choose XIAMEN APOLLO
Over 30 years of experience in electrical metal component manufacturing.
Integrated copper busbar + insulation processing + assembly production line;
Monthly production capacity of 50 million units, with fast delivery capabilities;
Fully certified to ISO9001, IATF16949, RoHS, and REACH;
Serving global customers in new energy vehicles, energy storage, power generation, rail transit, and industrial automation.
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