Insulated Pvc Custom Battery Bus Bar
Products Description
Insulated Pvc Custom Battery Bus Bars are engineering-grade conductive components designed for high-current connections within battery systems. They essentially consist of two parts:
An inner high-conductivity metal busbar: responsible for main current transmission.
An outer PVC-impregnated insulation layer: providing electrical isolation, environmental protection, and structural safety.
Compared to bare copper busbars or simple bushing insulation solutions, PVC-impregnated busbars offer significant engineering advantages in insulation integrity, consistency, environmental resistance, and assembly safety, making them particularly suitable for new energy systems with high safety and reliability requirements.
Refined Production Process: Every Step Adapts to Stringent New Energy Standards
1. Customized Solution Confirmation: In-depth collaboration with clients to clarify product specifications, form, installation requirements, and application scenarios, completing structural design and process plan development.
2. High-Purity Copper Substrate Selection: High-purity electrolytic copper ingots conforming to standards are selected. Copper purity and impurity content are tested using a spectrometer to ensure conductivity ≥99.9%.
3. Precise Substrate Forming: Copper material is cut according to the design scheme. The basic shape of the PVC Dipping Insulated Busbar is formed through CNC bending, stamping, and other processes. Simultaneously, mounting holes and positioning structures are processed to ensure dimensional accuracy meets standards.
4. Substrate Surface Pretreatment: The formed copper busbar undergoes degreasing, pickling, and phosphating treatments to remove surface oxide layers, oil, and impurities, improving the adhesion between the copper substrate and the PVC coating.
5. Preheating Treatment: The pre-treated copper busbar is placed in a constant temperature oven for uniform preheating, ensuring the substrate temperature reaches the optimal temperature for PVC powder melting and adhesion, guaranteeing coating uniformity.
6. Specialized PVC Dip Coating: The preheated PVC Dipped Insulated Bus Bar is immersed in a customized modified PVC powder bath. Electrostatic adsorption technology ensures the PVC powder evenly coats the copper substrate surface, controlling the coating thickness to meet design requirements.
7. Constant Temperature Curing and Gradient Cooling: The dip-coated busbar is placed in a curing oven for precise temperature curing of the PVC coating. A gradient cooling process is then used to slowly cool the product, preventing the coating from peeling off the substrate.
8. Post-Processing Finishing: After curing, the product undergoes edge trimming and burr removal to ensure a smooth and even appearance. Precise grinding is performed on installation areas to ensure assembly accuracy.
9. Finished Product Testing: Fifteen specialized tests are conducted, including insulation withstand voltage, temperature cycling resistance, vibration resistance, salt spray corrosion resistance, and flame retardancy. After passing these tests, the product is labeled, packaged, and stored.
Product Advantages: A Cost-Effective Choice Surpassing Traditional Connection Solutions
Extremely High Safety Redundancy
Compared to simple heat shrink tubing, the dip-molded PVC layer is thicker, seamless, and eliminates weak points caused by uneven shrinkage of heat shrink tubing. This one-piece structure significantly improves creepage distance, providing more reliable safety isolation within the confined space of the battery pack.
Low-Cost Implementation of Complex Geometry
For extremely complex 3D Plastic Dipping Copper Busbars (such as "tree-fork" busbars with multiple branches), traditional injection molding is expensive, and heat-shrink tubing cannot cover them. The dip-molding process eliminates the need for expensive molds; complex shapes can be easily covered with full insulation through fixture design, making it the most cost-effective solution for highly customized needs.
Production Efficiency and Delivery Speed
The dip-molding process is suitable for continuous mass production. Once the process parameters are set, production speed is extremely fast, meeting the explosive growth in production capacity demand in the new energy vehicle and photovoltaic industries, ensuring the security of customers' supply chains.
Vibration and Noise Reduction
In battery packs, resonance may occur between plastic-dipped copper Busbars or between copper busbars and the casing. The soft PVC layer acts as a pad and buffer, effectively reducing abnormal noises during vehicle operation and improving the overall NVH (noise, vibration, and harshness) performance of the vehicle.
Application Advantages: The Optimal Connection Solution for New Energy Vehicles and Photovoltaic Systems
In the new energy vehicle sector, our Dipping Busbar for Connections demonstrates unique value:
Power Battery Pack Connection: As a critical connector within the battery pack, they ensure the safety and reliability of high-current transmission, preventing system failures due to poor connections.
Vibration Environment Adaptability: New energy vehicles experience continuous vibration during operation; our products effectively absorb vibration, maintaining the integrity of the insulation layer and extending the battery pack's lifespan.
Thermal Management Optimization: The thermal resistance characteristics of PVC material aid in battery pack thermal management, reducing the risk of localized overheating and improving the overall efficiency of the battery system.
In photovoltaic system applications, our products also perform exceptionally well:
Photovoltaic Inverter Connection: Provides a safe and reliable power connection between the photovoltaic inverter and the battery pack, ensuring efficient power transmission.
Outdoor Environment Adaptability: Photovoltaic systems are exposed to outdoor environments for extended periods; the weather resistance of PVC material ensures the insulation layer remains stable under ultraviolet radiation, rain, and temperature variations.
Simplified System Integration: Standardized connection methods simplify the photovoltaic system installation process, reducing engineering complexity and improving installation efficiency.
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