PVC Insulated Copper Busbar
What is Thick Insulation for Enhanced Electrical Safety?
Essential positioning: The PVC Insulated Copper Busbar is a rigid, hard-connected current-carrying conductor. Its insulation layer is integrated with the copper bus matrix through a high-temperature melting process. It has the triple properties of electrical isolation, environmental sealing, and mechanical protection.
Core features:
Integrated melt coating: There is no peelable interface between the insulation layer and the copper bar. The PVC flows into the microscopic unevenness of the copper surface in the molten state, and forms a mechanical lock after cooling. The shear strength is much higher than that of sleeve-type coating.
No seams in all circumferences: The dip-molding process achieves 360° continuous coating, including the end face of the copper bar, the inner wall of the opening, and the inside of the complex bend. There are no longitudinal or transverse overlapping seams, eliminating electric field concentration and leakage channels.
Controllable wall thickness gradient: Through the coordinated regulation of dipping time, powder temperature, and copper bar preheating temperature, precise wall thickness design within the range of 0.5mm to 2.5mm can be achieved to meet the insulation coordination needs of different voltage levels.
Application advantages: Deeply explore core areas
New energy vehicle power battery pack
Used for inter-module connection, busbar, and battery pack total positive/total negative connection. It perfectly adapts to the complex three-dimensional wiring space in the battery pack, resists coolant corrosion, and ensures the insulation safety of the battery system during its life cycle of 10 years or 200,000 kilometers.
Photovoltaic inverter and combiner box
Used to connect high-current power modules inside the inverter. Excellent weather resistance enables it to adapt to harsh outdoor environments of high temperature, high humidity, and high ultraviolet rays, prevent electrochemical corrosion, and reduce operation and maintenance costs.
Energy storage system (ESS)
In large energy storage containers, plastic-impregnated busbars are used in high-voltage power distribution units. Their flame-retardant properties effectively prevent the spread of thermal runaway and comply with strict fire protection standards for energy storage systems.
Rail transit and industrial automation
It is used to connect traction converters and servo drives to achieve large current transmission in a narrow space and has excellent anti-vibration performance.
Detailed Display
| Surface leveling texture | The surface of the high-quality impregnation layer presents a uniform and delicate orange peel texture or a high-gloss mirror effect, with no sagging, no bubbles, and no pinholes. Under side light illumination, the surface reflection is continuous and even, without any concave or convex defects. |
| Thickness consistency in the bending area | On the inside of the 90° bend of the copper bar, there is no thinning or stacking of the plastic-impregnated layer, and the difference between the wall thickness and the straight section is controlled within ±15%. This requires a uniform preheating temperature of the copper bars and a stable fluidization state of the powder during dipping. |
| Integrity of opening edge covering | The plastic-impregnated layer on the edge of the punching hole completely wraps the hole wall, with no exposed copper or cracks. The hole has a natural arc transition, and there is no PVC molten dripping to block the hole diameter, ensuring smooth penetration of the bolts during stacking. |
| End transition accuracy | The end shrinkage position of the insulation layer is neat, the boundary between the bare copper exposed area and the insulation area is clear, the transition area is slightly tapered, and there is no step-like mutation. If the end face is exposed through post-processing, the cut surface will be smooth, and there will be no peeling or peeling of the insulation layer. |
Frequently Asked Questions
Q1: What is Custom Solid Power Bus Bar with Insulated Dipping Tube used for?
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PVC Insulated Copper Busbar is mainly used for electrical power distribution and high-current connection in EV battery packs, solar PV systems, energy storage systems, and industrial electrical equipment.
Q2: What is the difference between PVC insulated busbar and bare copper busbar?
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PVC insulated copper busbar adds an insulation layer on the copper conductor, providing better electrical protection, improved safety and easier installation compared with traditional bare copper busbar.
Q3: Can you customize copper busbar dimensions and insulation design?
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Yes. We provide customized solutions including copper thickness, width, bending structure, terminal design, hole position and PVC insulation requirements based on customer drawings or application conditions.
Q4: What manufacturing processes are available for PVC insulated copper busbar?
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Our production processes include copper cutting, stamping, bending, surface treatment, PVC coating, inspection and performance testing to ensure stable quality for industrial applications.
Q5: Which industries commonly use Insulated Flat Copper Busbar?
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It is widely used in electric vehicles, battery energy storage systems, solar power systems, power electronics and high-voltage electrical equipment.
contact us
If you are developing new energy vehicles, energy storage, or photovoltaic projects and need high-reliability PVC Insulated Copper Busbar for Electrical Connections solutions, we can provide professional engineering support and customized manufacturing services based on your structural design, electrical parameters, and application environment.
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