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Plastic Dipping Copper Busbar

In the "last mile" of industrial power transmission, the Plastic Dipping Copper Busbar redefines the reliability standard for power connections with its innovative fusion of "copper-based conductivity + plastic protection." Rather than simply stacking a traditional copper busbar with an insulating layer, the Plastic Dipping Copper Busbar combines high-purity copper with a polymer plastic layer through a plastic dipping process, creating an integrated structure with "internal conductivity and external protection." When equipment faces moisture, dust, chemical corrosion, or requires multi-scenario switching, the traditional copper busbar's "exposed conductivity + post-protection" model often poses safety risks due to interface separation, aging, and failure. The Plastic Dipping Copper BusBar, with its integrated protection, lightweight structure, and diverse adaptability, fundamentally addresses the industry's pain points of weak insulation, cumbersome maintenance, and poor environmental adaptability. It has become the preferred technology of leading manufacturers in new energy equipment, industrial automation, rail transit, and other fields.

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Products Description

Plastic Dipping Copper Busbars are key conductive components widely used in new energy, power distribution, energy storage systems, rail transit, and industrial electrical equipment. Their main body is molded from high-quality electrolytic copper or oxygen-free copper, and a surface-plasticization process creates a uniform, dense insulating protective layer, achieving both high conductivity and high insulation. Compared to traditional bare copper busbars, plastic-dipped copper busbars offer significant advantages in safety, service life, and ease of installation.

As a next-generation electrical connection solution, they not only effectively reduce contact resistance and energy loss but also maintain stable operation in harsh environments, meeting the diverse needs of new energy battery systems, distribution cabinets, high-voltage electrical equipment, and more.

Product Features and Properties

Excellent Conductivity	Processed from high-purity electrolytic copper, Copper Busbar Insulated with PVC Dip ensures low resistivity and high conductivity, ensuring efficient and stable power transmission.
Insulation Coating	The surface is uniformly coated with a wear-resistant and high-temperature-resistant PVC or PE coating, providing comprehensive electrical insulation protection and effectively preventing short circuits and accidental electric shock.
High Mechanical Strength	The copper substrate offers excellent bending and fatigue resistance, while the coating enhances overall impact resistance, making Nickel Plated Cu Insulated Tube PVC Dipping BusBar suitable for long-term operation.
Flexible Customization	Custom sizes, thicknesses, hole positions, and bending shapes can be customized according to customer drawings or system requirements to meet complex electrical connection scenarios.
Excellent Corrosion Resistance	The coating isolates air and moisture, preventing oxidation on the copper surface and extending its service life.

Dip Insulated Busbar

Scenario-Specific Selection of High-Purity Copper Substrate

T2 copper substrate

Purity ≥ 99.95%, conductivity up to 98% IACS, suitable for low to medium current (100A-1000A) applications, such as data center server power busbars. Its excellent conductivity reduces current transmission losses, while its good ductility allows for easy processing into PVC Dipping Insulated Busbars of varying cross-sections, adapting to the compact installation spaces of data centers.

C1100 oxygen-free copper substrate

With an oxygen content of ≤0.003% and extremely low impurity content, it offers superior conductivity to T2 copper and lower signal attenuation during high-frequency current transmission. It is suitable for busbar systems used in high-frequency rectifiers and precision instruments (such as power PVC Coated Bus Bars for medical devices), ensuring stable and accurate current transmission.

CuAg0.1 silver-copper alloy substrate

With a silver content of 0.08-0.12%, it maintains 95% IACS conductivity while offering a 25% increase in mechanical strength (tensile strength ≥300MPa) and significantly enhanced wear resistance. It is suitable for high-current (1000A-5000A) applications requiring frequent maintenance, such as main Dip Insulated Busbars in outdoor energy storage stations, to prevent busbar deformation caused by mechanical stress.

Application Advantages: Widely applicable in diverse industrial scenarios

01/

New energy vehicles and charging stations

Used for internal connections in battery packs, providing insulation protection and short-circuit protection, and adapting to vibration and temperature fluctuations.

02/

PV inverters and energy storage systems

Used at DC Insulated Busbar connection points, they prevent leakage risks in humid environments and enhance system safety.

03/

Industrial control cabinets and distribution boxes

Used as power PVC Dipping Insulated Busbars in PLCs, inverters, and UPSs, they simplify wiring, improve cabinet cleanliness, and enhance safety.

04/

Railway and marine power systems

Meeting stringent standards for flame retardancy, low smoke, and vibration resistance, they are used in key areas such as traction systems and auxiliary power supplies.

05/

Medical equipment and high-end instruments

Provide clean and safe power connections, prevent accidental electric shock, and comply with medical electrical safety regulations.

06/

Automated production lines and robotics

Provide flexible insulation protection during power transmission between moving parts, preventing cable abrasion.

Application Area for Plastic Dipping Copper Busbars