Detailed description and advantages of fully PET-insulated copper busbars

Fully insulated shielded copper tube busbars are high-performance busbar conductor systems that use copper tubes as the conductive core and a composite insulation system for complete enclosure shielding. In some applications, they are also referred to as tubular cables. This structure combines copper tube conductors with multi-layer insulation to achieve a balance between high current transmission and high electrical safety levels, and is widely used in medium- and high-voltage power distribution systems and high-current transmission applications at voltage levels from 0.4kV to 35kV.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Structurally, this type of busbar uses high-purity copper as the base conductor, typically employing copper with a purity of≥99.9% to create a tubular conductor structure. This optimizes current distribution characteristics while maintaining conductivity. The copper tube structure makes the current distribution more uniform across the cross-section, reducing the skin effect and thus improving overall current-carrying capacity and operating efficiency. Its conductor form can also be seen as a combination of a solid-insulation tubing busbar and a high-performance conductor structure.

 

In terms of insulation systems, fully insulated copper tube busbars typically employ a multi-layer composite insulation structure. A complete outer insulation layer is formed through heat shrinking, extrusion, or lamination processes, such as PE heat-shrink tube insulated busbars or heat-shrink tubed busbars, to achieve complete conductor coverage and uniform electric field control. Some designs may also incorporate PVC-insulated busbars or PVC busbar heat-shrink sleeves to enhance environmental adaptability and mechanical protection.

 

This type of busbar offers significant advantages in electrical performance. Its rated current-carrying capacity can reach high levels, meeting the operating requirements of thousands to tens of thousands of amperes in large power systems. Due to the hollow structure of the copper tube, its large external surface area facilitates heat dissipation and air convection, resulting in a significantly lower temperature rise compared to traditional rectangular busbar structures. Simultaneously, the enclosed insulation design ensures a uniform external electric field distribution, significantly reducing the risk of partial discharge and phase-to-phase short circuits.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In terms of mechanical performance, copper tube busbars possess high structural strength, and their bending resistance and short-circuit electrodynamic resistance are significantly superior to the rectangular conductor structures offered by traditional busbar system manufacturers. Under short-circuit impact conditions, its structure exhibits higher stability, capable of withstanding significant electrodynamic shocks without deformation or failure, making it suitable for substation and distribution systems with high safety requirements.

 

Regarding operational reliability, the fully insulated shielded structure completely isolates the conductor from external environmental influences, effectively preventing insulation degradation caused by moisture, dust, salt spray, and other factors. This characteristic is particularly important in highly polluted or humid environments, making it highly valuable in AC BusBar and High Voltage BusBar systems. Simultaneously, the enclosed structure reduces reliance on external support structures and insulator systems, improving system integration.

 

From a system application perspective, this type of busbar can be widely used in Distribution BusBar systems, Low Voltage BusBars, and high-voltage distribution systems, as well as in high-current DC connection structures related to EV Battery Connectors and EV Battery Connectors. In new energy and energy storage systems, its structural advantages allow it to replace traditional cables or open copper busbar connections, improving system safety and maintenance efficiency.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

At the engineering design level, these products are typically customized based on current ratings and installation environments, such as Custom BusBar or Customized Busbar Insulating Tube structures, to meet the needs of different equipment layouts and electrical parameters. In some industrial systems, they can also be used in conjunction with Battery Terminal Bus Bar or Positive and Negative Bus Bar structures to achieve efficient integration of DC busbar systems.

 

Regarding the selection of insulation and protection materials, in addition to heat-shrinkable structures, Busbar Insulation Sheets or Busbar Insulating Tubing can be used for auxiliary insulation design to improve the overall insulation level and aging resistance. For special applications, Busbar Sleeves Insulation or Heat Shrink Sleeves BusBar structures can be used to enhance local protection capabilities.

 

From a long-term operating perspective, fully insulated copper tube busbars offer a long service life and low maintenance requirements. Their material system has good heat resistance and chemical stability, maintaining stable operation even under complex electromagnetic environments and temperature fluctuations. Under proper design and installation conditions, long-term maintenance-free operation can be achieved, making them suitable for industrial and infrastructure systems with high requirements for power supply continuity. In applications involving various brands of equipment, this type of busbar can be used in the interface structures of systems such as BusBar for Siemens, BusBar for ABB, BusBar for Eaton, BusBar for Weidmuller, and BusBar for Mersen Ferraz, serving as a standardized or customized conductive connection unit. Copper BusBar manufacturers and suppliers can also provide products with corresponding specifications for integration into different electrical systems.

 

Overall, fully insulated shielded copper conduit busbars, through the combination of optimized conductor structure and fully enclosed insulation design, significantly outperform traditional busbar structures in terms of current carrying capacity, mechanical strength, thermal management performance, and operational reliability, making them one of the important conductive solutions in modern high-voltage power distribution and new energy power systems.