Four Process Technologies For The Insulation Layer Of New Energy Flexible Discharge Tubes

Against the backdrop of the rapid development of new energy power systems, battery energy storage systems, and rail transit equipment, flexible busbars are becoming key conductive components in high-voltage connection systems due to their high conductivity, flexible installation capabilities, and excellent heat dissipation performance. Especially in high-voltage, high-current applications, the insulation process directly affects system safety, withstand voltage, and long-term operational stability. Therefore, new energy flexible busbar insulation technology is becoming a key focus in industry R&D and engineering design.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

As new energy vehicle platforms gradually upgrade to 800V or even higher voltage platforms, the importance of insulation structure design is further enhanced. In high-voltage environments, improper selection of insulation materials or unstable processing techniques can lead to partial discharge, insulation aging, and even breakdown risks. Therefore, the industry has developed various mature insulation processing technologies for flexible connection products with different structural forms to meet the electrical safety requirements under complex operating conditions.

 

Currently, common flexible connection insulation processes in the new energy industry mainly include four types: heat shrink tubing, dip molding, extrusion, and injection molding. Different processes are suitable for different structures and application requirements.

 

Heat shrink insulation is currently the most widely used solution. This process typically involves wrapping PVC or heat-shrinkable insulation material around a copper busbar or copper foil flexible connector, followed by high-temperature heating to achieve shrinkage molding. Its advantages include mature technology, high processing efficiency, and good cost control, making it suitable for conductive connectors with regular structures and low bending difficulty. Common industry products such as Heat Shrink Tubing, Busbar, and Insulated Copper Busbar with Heat Shrink Tube employ similar structural designs. This process is widely used in energy storage devices, battery modules, and standardized conductive connection systems.

 

In some complex structural products, where irregular bending angles are large, traditional heat-shrinking methods find it difficult to achieve a complete fit. In such cases, dip coating becomes an important solution. Dip coating involves using high-temperature liquid PVC material to completely encapsulate the copper busbar, ensuring the insulation layer evenly covers complex structural areas. The resulting insulation layer has a smooth surface, strong adhesion, and good wear resistance and moisture resistance, making it widely used in the field of irregularly shaped busbars in new energy vehicles. Some Copper Busbar PVC Insulated products and Busbar With PVC Insulation solutions typically employ this processing method.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In recent years, with the improvement of automated manufacturing levels, extrusion insulation technology has rapidly become widespread in the mass production of busbars. Extrusion technology directly coats insulating materials onto the conductor surface using continuous equipment, enabling high-speed production of long-sized products. This process is suitable for continuous conductive structures in large-scale power distribution systems, power equipment, and high-voltage energy storage systems. Common materials include engineering insulation materials such as PVC and PA12. Solid Insulation Tubing Busbar, and Insulated Flexible Busbar with PVC Insulation products in the industry typically combine extrusion processes to improve insulation consistency and batch stability.

 

For some complex multilayer busbar systems with high requirements for insulation appearance and dimensional accuracy, injection molding is required. Injection molding insulation technology completes the insulation layer molding in one step using customized molds, enabling precise coverage of complex structural areas and improving overall mechanical protection capabilities. This type of process is widely used in high-voltage battery systems, energy storage control systems, and large power modules. Because it is compatible with various high-performance materials, it has high application value in high-end new energy systems.

 

As the safety standards requirements of the new energy industry chain continue to rise, the insulating materials themselves are also constantly being upgraded. Currently, materials widely used in the industry not only need to meet pressure resistance requirements but also need to possess properties such as flame retardancy, resistance to high and low temperatures, chemical corrosion resistance, and environmental friendliness. Most high-voltage flexible connection insulation solutions must meet the UL94 V-0 flame retardant rating to ensure long-term stable operation of equipment under complex conditions.

 

Meanwhile, the increasing demands for connection efficiency and space utilization in new energy battery systems are driving the development of insulating busbars towards lightweighting, flexibility, and high integration. Products such as EV Battery Connectors, Battery Terminal Bus Bars, and Positive and Negative Bus Bars are being widely used in power battery packs, energy storage integrated systems, and high-voltage electronic control platforms.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Furthermore, to address insulation protection needs, the industry has developed various auxiliary insulation solutions. Products such as PVC Busbar Heat Shrink Sleeves, PVC Heat Shrinkable Sleeves for Busbars, and Heat Shrinkable Busbar Insulating Tape can further enhance the safety and environmental adaptability of conductive systems.

 

From an industry development perspective, future new energy flexible connection insulation technology will continue to evolve towards higher withstand voltage levels, lighter structures, and more intelligent manufacturing. For engineering R&D personnel, a deep understanding of the structural characteristics, material properties, and applicable scenarios of different insulation processes will help optimize product design, improve system reliability, and meet the ever-growing demand from the new energy industry for highly safe and efficient conductive systems.