Plastic Dipping Electric Copper Busbar Custom Made
Products Description
The Plastic Dipping Electric Copper Busbar Custom Made is a specialized electrical interconnection component featuring a conductive core made of high-conductivity pure copper or copper alloy bars, which is entirely encapsulated on its surface with a high-performance engineering plastic insulating layer using an immersion molding process. This product is specifically designed for applications-such as new energy vehicles, energy storage systems, and photovoltaic inverters-that impose stringent requirements regarding insulation reliability, spatial compactness, and environmental resistance; it enables high-current, low-loss, and high-safety power transmission within complex three-dimensional structures and high-voltage environments.
Product Properties and Characteristics
| Electrical Characteristics | High insulation resistance, high dielectric strength, low dissipation factor, and excellent resistance to electrical tracking for Soft Connection Copper Busbar. |
| Mechanical Characteristics | Strong adhesion between the insulation layer and the conductor; the overall structure strikes a balance between rigidity and toughness, offering excellent resistance to abrasion and impact. |
| Thermal Characteristics | The insulating material possesses a specified thermal rating (e.g., PA can withstand temperatures of 120–140°C) and exhibits excellent thermal stability for Plastic Dipping Copper Busbar. |
| Safety Characteristics | Flame-retardant (typically UL94 V-0), non-toxic, and compliant with environmental regulations such as RoHS for Dipping Busbar for Connection. |
Dip Coating Process
Uniform Preheating
Prior to immersion, the PVC Coated Bus Bars must be preheated in an oven-uniformly and in its entirety-to a temperature exceeding the melting point of the plastic powder. Non-uniform temperatures can result in localized variations in the amount of powder adsorbed.
Fluidized Bed Control
The plastic powder within the fluidized bed is maintained in a uniform and stable "boiling" state, ensuring that the powder concentration in contact with every part of the Busbar Isolation remains consistent.
Processing and Post-treatment
Following immersion, excess powder is removed through rotation and vibration. The busbar is then cured in a curing oven, undergoing uniform heating at a controlled rate to allow the molten plastic to naturally level out under the influence of surface tension. For exceptionally thick components or those with highly complex geometries, a multi-dip coating process may be employed. The final Dip Insulated Busbar coating thickness undergoes 100% inspection using an ultrasonic thickness gauge.
Key Functions
Current Transmission
As a core conductive component, Soft Connection Copper Busbar facilitates the efficient and stable transmission of high currents. Leveraging a high-purity copper substrate, it minimizes energy loss during transmission, thereby ensuring that terminal equipment-such as new energy vehicles and photovoltaic systems-receives a stable and sufficient power supply, guaranteeing their normal operation.
Insulation and Protection
A seamless insulating barrier is formed by a surface dip-coating layer, effectively isolating the Plastic Dipping Copper Busbar from external conductors and environmental media. This prevents safety hazards such as current leakage and short circuits, while simultaneously protecting the busbar body from oxidation and corrosion, thereby ensuring the product's long-term, stable performance.
Circuit Connection
Dipping Busbar for Connection establishes reliable electrical connections-both within the internal circuitry of terminal devices and between separate devices. Characterized by tight, secure connections and low contact resistance, it prevents issues such as overheating and arcing caused by poor contact, thereby ensuring unimpeded circuit flow.
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