Insulating Busbar

 

Insulated copper busbars require stable electrical conductivity, controlled mechanical dimensions, and reliable insulation protection under high-current operating conditions. Apollo manufactures customized insulated copper busbars using C1100 pure copper and T2 electrolytic copper materials selected for their high conductivity, thermal performance, and forming characteristics.

C1100 pure copper provides electrical conductivity up to 100% IACS, helping reduce resistive losses and temperature rise during continuous current transmission. The copper thickness, width, and cross-sectional area are designed according to customer current requirements, installation space, and thermal management conditions.

Before insulation processing, copper busbars are produced through precision cutting, punching, CNC bending, and forming operations.

 

Apollo applies springback compensation during copper bending to maintain dimensional accuracy after forming, especially for complex three-dimensional busbar structures used inside EV battery packs and ESS cabinets.

For high-volume projects, progressive stamping dies and dedicated tooling systems ensure repeatable production quality. Critical dimensions are controlled within ±0.01mm tolerance according to drawing requirements.

The insulation structure is selected according to voltage level, environment, and assembly requirements:

PET insulation paper: Commonly selected for laminated insulation structures. Apollo supports materials from international insulation paper suppliers such as USA GTS and Germany KREMPEL. Available colors include white and milky white.

PVC dipping insulation: Suitable for irregular copper busbar geometries requiring complete surface coverage. Orange and green are commonly used for electrical identification.

Epoxy powder coating: Provides strong adhesion, chemical resistance, and high dielectric performance for high-voltage applications.

PE heat shrink tube: Provides flexible protection for curved copper busbars with options including orange, green, black, red, and yellow.

PA66 plastic housing: Provides mechanical protection and positioning support in compact electrical assemblies.

 

 

Parameter	Specification
Copper Material	C1100 Pure Copper / T2 Copper
Electrical Conductivity	Up to 100% IACS
Copper Thickness	Customized according to current rating
Machining Tolerance	±0.01mm
Copper Forming Process	CNC Bending / Progressive Stamping / Punching
Insulation Options	PET Paper / PVC Dipping / Epoxy Powder / PE Tube / PA66 Housing
Dielectric Performance	Dielectric Breakdown Voltage Testing
Epoxy Coating Thickness	Customized according to voltage requirements
Flame Rating	UL94 V-0 Available
Application Voltage	EV Battery / ESS / Power Distribution Systems

 

 

The insulation performance of copper busbars directly affects electrical safety in high-voltage systems. Apollo provides multiple insulation solutions based on voltage class, environmental conditions, and mechanical installation requirements.

For PET insulation paper busbars, the insulation layer is precisely positioned between copper conductors to maintain electrical separation and reduce the risk of short circuits. PET materials provide stable dielectric properties and mechanical strength under repeated thermal cycling.

For epoxy powder-coated copper busbars, electrostatic powder spraying technology creates a uniform insulation layer around copper surfaces. The coating provides:

High dielectric strength
Moisture resistance
Chemical resistance
Mechanical protection against abrasion

Epoxy insulation systems can achieve dielectric breakdown performance above 15kV/mm depending on coating thickness and material specification.

For PVC dipping copper busbars, the liquid insulation process covers complex copper geometries including holes, bends, and irregular profiles. This method is suitable for applications requiring full electrical isolation and environmental protection.

For PE heat shrink insulated busbars, the tubing structure provides flexible protection while maintaining compact installation dimensions. The heat shrink layer is suitable for battery modules, power distribution units, and electrical cabinets where vibration resistance is required.

PA66 plastic housings are applied when the busbar requires additional mechanical positioning, touch protection, or assembly guidance.

Apollo also provides surface treatments including tin plating, nickel plating and silver plating when improved oxidation resistance or electrical contact performance is required.

 

Request Custom Technical Evaluation

 

 

Apollo controls insulated copper busbar production through material inspection, forming process monitoring, insulation verification, and final electrical testing.

Incoming copper materials are inspected for chemical composition, thickness, and electrical conductivity. During production, dimensional accuracy is verified using precision measurement equipment, including CMM systems and optical image inspection equipment.

For customized insulated busbar projects, Apollo provides quality documentation according to automotive supply chain requirements:
PPAP Level 3 submission
Process Flow Diagram
PFMEA
Control Plan
Material Certificate
CPK Process Capability Analysis

Production inspection includes:
Dimensional Inspection
Hexagon / Zeiss CMM measurement
Measurement accuracy up to 0.0007mm
Optical image dimension inspection
Critical tolerance verification

Electrical Performance Testing
Electrical conductivity testing
Insulation resistance testing
High voltage withstand testing
Dielectric breakdown voltage verification
Temperature rise testing under current load

Environmental Reliability Testing
Thermal cycling test
Humidity resistance evaluation
Mechanical vibration verification

Apollo operates according to IATF 16949:2016 and ISO 9001 quality management systems to support automotive, EV battery and energy storage supply chains.

 

 

 

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