최고의 적층 버스바 제조업체 및 공급업체

We provide high-performance laminated busbars specifically designed for industrial applications, which are made of multiple layers of high-purity copper or aluminum through a precision lamination process, combining ultra-low resistance and high heat dissipation characteristics. The products support full-dimensional customization (shape, size, curvature) to flexibly adapt to complex space layouts; corrosion-resistant and anti-mechanical stress design to adapt to high and low temperatures, vibration and other harsh working conditions. We have passed IEC 61373 and other international certifications, and implemented zero-defect control in the production process to ensure that each product has a voltage resistance of >5kV and a life span of >100,000 cycles. They have been successfully applied in power generation system, new energy vehicle triboelectric system, aerospace equipment and other scenarios, providing standardized and customized solutions for highly reliable power transmission.

구리 호일 적층 버스 바

Shunk 코팅 적층 구리 버스 바

유연한 적층 구리 버스바

전문 구리 버스 바 공급업체

적층 버스바는 전력 분배를 위한 다양한 전기 시스템에 사용되는 필수 구성 요소입니다. 공장으로서 우리는 적층 버스바를 제공하며 일반적으로 다양한 산업 요구 사항에 맞는 다양한 제품과 서비스를 제공합니다. 이러한 제조업체에서 기대할 수 있는 몇 가지 주요 기능과 제공 사항은 다음과 같습니다.

주요 기능 및 서비스

사용자 정의:

1. Parameter and material selection

• Conductive material: Electrolytic copper (purity ≥99.9%) or aluminum, copper foil thickness range 0.03-0.3mm, aluminum needs to meet the tensile strength ≥379N.
• Insulation material: choose polyimide (PI, temperature resistance >200°C) or polyester (PET, low cost and high CTI) according to the demand of temperature resistance, and the flame retardant grade reaches UL V0.
• Structural design: support L-type, U-type and other shaped customization, flexible busbar for dynamic scenarios (e.g. rail transit), rigid busbar for fixed installation (e.g. substation).

2. Process optimization

• Lamination parameters: Adjust temperature (160-180°C), pressure (6-10MPa), time, etc. through experimental verification, combined with vacuum pumping (≥5 minutes) to avoid air bubbles.
• Integrated design: For example, CCS integrated busbar (FPC+aluminum busbar+blister bracket) can replace the traditional wiring harness to achieve automated assembly and space optimization.

3. Special Demand Response

• High temperature/low inductance: 220°C resistant insulating material and low dielectric binder for SiC/GaN power modules.
• Intelligent monitoring: Integrated flexible circuit and thermal sensor to realize real-time monitoring of battery pack voltage and temperature.

제조 능력:

1. Production capacity scale: Annual production capacity reaches more than 300,000 pieces of traditional composite busbars and 1,000,000 pieces of integrated busbars (upgraded to 2,000,000 pieces after newly added production lines).
2. Production process efficiency: Adopting automated hot press laminating production line, it supports the delivery of large-volume orders, and the cycle time can be shortened to 24 hours (for urgent orders

테스트 및 품질 보증:

1. Test Items

• Electrical performance: Resistance (≤0.5mΩ/m), inductance (≤0.1μH/m) test; Local discharge test (PD test), voltage withstand level up to 5kV or above.
• Mechanical properties: Bending life ≥100,000 times (flexible busbar), vibration test in accordance with IEC 61373 standard.
• Environmental reliability:  Salt spray test (corrosion resistance), high and low temperature cycling (-40°C to 200°C).

2. Quality assurance measures

• Process control: first piece inspection, process inspection, full inspection of finished products, combined with FMEA (Failure Mode Analysis) and DFM (Design for Manufacturability) techniques.
•  Equipment Maintenance: Regular calibration of laminator temperature and pressure parameters, cleaning of vacuum pumps and cooling systems.
• Certification standards: ISO 9001 (quality management), AS9100C (aerospace) and other certifications, some manufacturers have IRIS (rail transportation) certification.

3. After-sales guarantee

• Provide more than 5 years service life commitment, regular maintenance recommendations (such as infrared temperature measurement, pressure resistance retest).
• Non-conforming products processing: isolation analysis → process adjustment → rework / scrap → data traceability improvement.

Laminated Busbar Production Process:

1. Raw material preparation:

• Conductive layer: Copper/Aluminum foil cut, polished, plated (tin/silver plated).
• Insulation layer: Polyester film or epoxy prepreg cut.

2. Stacking and Lamination:  Alternate stacking of conductive and insulating layers, curing and molding by hot press at high temperature (160°C-180°C) and high pressure (6-10MPa).

3. Welding and Assembly: Laser welding or resistance welding to connect the terminals, assembly of insulated brackets and connectors.

4. Quality Testing: Conductivity test (resistance, inductance), insulation withstand voltage test (≥3kV), mechanical strength test.

적층 버스바 응용 프로그램:

• Power System: Substation, Smart Grid, Extra High Voltage Transmission
• New Energy: Photovoltaic inverters, wind turbines, energy storage systems
• Industrial Automation: Inverters, Welders, Machine Tool Power Transmission
• Transportation: Electric Vehicle Battery Connections, High Speed Rail Traction Systems
• Data Center: Server Cabinet Power Distribution, UPS Uninterruptible Power Supply

적층 버스바는 여러 가지 장점을 제공합니다.

1. Efficient Conductivity: Multi-layer structure reduces resistance and inductance to minimize energy loss.
2. Excellent heat dissipation: Flat design increases the heat dissipation area, and the temperature rise is 30%-50% lower than the traditional bus bar.
3. Compact and flexible: 50% less volume than cable, supports customized shapes (e.g. L-type, U-type).
4. Safe and reliable: insulation layer is resistant to high temperature and aging, and the protection level reaches IP65.
5. Environmental protection and energy saving: lead-free process, material recycling rate ≥95%.

자주 묻는 질문

Q1: What are the advantages of laminated busbar over cable?
A: Laminated busbar has higher current density (up to 2-3 times that of cable) and no skin effect, which makes it suitable for high-frequency scenarios.

Q2: How to solve the air bubble problem in production?
A: Optimize the vacuum pumping time (suggested ≥5 minutes), control EVA water content ≤0.3%, and use surface embossed film to enhance the exhaust.

Q3: What is the selection basis of flexible busbar and rigid busbar?
A: Flexible busbar is suitable for dynamic environment (e.g. rail transportation), and rigid busbar is used for fixed installation scenarios (e.g. substation).

Q4：Insulation material choose PET or PI?
A: PET has low cost and high CTI (for high voltage), PI has better temperature resistance (>200°C) and is suitable for welding scenarios.

Q5: How to maintain the laminated busbar?
A: Regular infrared temperature measurement (hot spot ≤70°C), clean insulation surface, and voltage resistance retest every 5 years.