Flexible Insulated Copper Busbar

√  Excellent electrical conductivity for efficient power transmission.

√  Flexibility allows for easy installation and routing in configurations.

√  Insulation layer ensures safety by preventing electrical shocks.

√  Versatile design suitable for various low-voltage applications.

√  Customizable sizes and configurations to meet project requirements.

Leading Flexible Insulated Copper Busbar Manufacturer

As an IATF 16949 certified manufacturer of flexible insulated copper busbars, we rely on fully automated production lines and UL standard laboratories to achieve product skin effect optimization and 1μm level insulation layer control. Specialized in new energy charging pile, IDC data center and other scenarios, the current carrying capacity is increased by 45% compared with traditional solutions, and supports -50℃~180℃ wide range temperature control. We provide customized solutions for cross-section/bending radius, deliver samples in 72 hours, and support a full life cycle technical response system to empower customers to build zero-fault power distribution networks.

How is production process for flexible insulated copper busbar?

1. Efficient power transmission

• Multilayer conductor structure reduces skin effect, and the current-carrying capacity is 30%-50% higher than that of cables with the same cross-section.
• No eddy current design, low line loss, power transmission efficiency of more than 99%.

2. Flexible installation

• Can be bent and laid in narrow spaces, reducing 90% of joints, and improving construction efficiency by 60%.
• Support outdoor, underground and other complex environments, without the need to reserve space for installation.

3. Safe and reliable

• Insulation breakdown voltage ≥20kV/mm, the outer sheath has no inductance, reducing the risk of electric shock.
• Resistant to corrosion, acid and alkali, suitable for chemical industry, metallurgy and other harsh environments.

4. Economy

• Copper consumption is reduced by 10%-20%, construction and maintenance costs are reduced by more than 50%.
• Lifetime maintenance-free, failure rate is only 1/5 of traditional busbar.

What are the key benefits of using flexible insulated copper busbars?

1. Raw material treatment

• Pre-treatment of copper: Continuous casting and rolling of copper rods are straightened and deslagged, and then drawn into copper strips or stranded copper wire rows.
• Insulation material proportioning: mix PVC, TPE, etc. according to the demand to ensure flame retardant and weatherproof performance.

2. Conductor molding

• Laminated or stranded: multiple layers of copper tape are laminated or stranded to form a flexible conductor core.

3. Insulation Overlay

• Process: Extrusion or impregnation process, uniform coverage of insulation layer, thickness 1.5-2.1mm.
• Special treatment: some products add metal armor layer (such as aluminum alloy) to enhance pressure resistance.

4. Testing and Packaging

• Testing items: voltage resistance test (above 3.5kV), temperature rise test, salt spray test (above 240 hours).
• Packaging: moisture-proof and shock-proof treatment, support customized marking.

In which applications are flexible insulated copper busbars commonly used?

• New energy: Super charging station (e.g. Huawei 600kW liquid-cooled super charging), photovoltaic energy storage system, to solve the high-power power supply needs.
• IDC server room: High load capacity to support server clusters, good heat dissipation to avoid local temperature rise, space saving.
• Railway transportation: Adapt to tunnels, bridges and other complex terrain, anti-vibration performance.
• Military and Aerospace: Resistant to extreme temperature and radiation, in line with the standards of autonomous control and high reliability.
• Industry and construction: High-rise building power distribution, metallurgical and chemical equipment power supply, replacing traditional cables and rigid bus ducts.

What materials are used for insulation?

• PVC (polyvinyl chloride): Low cost, good flame retardant, but contains halogens and releases toxic gases when burned.
• TPE (thermoplastic elastomer): Environmentally friendly materials, low smoke and halogen-free, wide range of temperature resistance (-40 ℃ to 105 ℃).
• Silicone composite materials: High temperature resistance (-60°C to 200°C), excellent flexibility, used in high demand scenarios such as military industry.
• Epoxy Resin :High mechanical strength, suitable for high-pressure environments, but at a higher cost.