Copper Busbar Powder Coating
Copper busbar powder coating refers to electrical interconnect components made of high-purity copper as the substrate, which are formed by electrostatic spraying of epoxy powder and high-temperature curing. This product is a core structural component for achieving high current and high voltage transmission in new energy vehicles, photovoltaic energy storage, rail transit, and power distribution systems.
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Product Introduction
Copper busbar powder coating is a customized high-voltage power transmission core component designed specifically for high-end engineering scenarios such as new energy, power systems, and rail transit. It uses high-purity copper substrate as the conductor and forms a dense protective layer through various insulation processes such as epoxy powder spraying. It combines the high conductivity of copper substrate with the safety protection characteristics of insulation materials, completely solving the industry pain points of traditional bare copper busbars such as insufficient insulation reliability, poor spatial adaptability, weak vibration tolerance, low environmental weather resistance, and high operation and maintenance costs.
Product features
Integrated composite structure
Copper busbar powder coating uses high-purity copper as the main conductive substrate, and adopts a composite molding method of chemical bonding of epoxy powder, heat shrink tubing, and physical coating of insulation paper. The insulation layer is tightly bonded and has strong integrity, without peeling bubbles or insulation failure hazards, and can stably adapt to complex industrial conditions.
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Global standards are fully compatible
Epoxy powder coating insulated busbar is strictly produced in accordance with multiple national material standards such as GB, DIN, EN, ISO, JIS, etc., and fully complies with ISO9001 and IATF16949 quality system specifications, meeting the compliance requirements of various engineering projects and equipment procurement at home and abroad.
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Wide temperature, weather resistance, stability, and durability
The Electroplating and powder coating bus is suitable for a wide range of operating temperatures from -45 ℃ to+150 ℃, and can withstand high-frequency vibration, alternating cold and hot, humid environment and mild chemical corrosion. It has excellent anti-aging and deformation resistance, ensuring long-term continuous operation and reliability.
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Full dimensional customization capability
Support comprehensive customized design of substrate grade, external structure, surface treatment, insulation process, and installation accessories, which can be adapted to the layout and assembly needs of different high-voltage systems such as new energy vehicles, energy storage equipment, and power cabinets as needed. Supports full custom options to fit diverse installation scenarios.
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Core technical features
Composite insulation technology
The epoxy powder coating forms a chemical bond with the copper substrate, which is different from the physical bonding of heat shrink tubing. The adhesive force is stronger, and the insulation layer is not easily peeled off or damaged. Under high-frequency vibration conditions, the insulation stability of the Insulation coating busbar is significantly improved.
Accurate current carrying technology
Based on the conductive characteristics of high-purity copper substrate, it accurately adapts to 100A-2000A load current and 3500VDC-5000VDC load voltage. The current carrying capacity of Epoxy powder coating busbar is stable, and the power loss is far below the industry average level, maximizing system efficiency.
Environmental weather resistance technology
Through material and process upgrades, Powder coated busbars can withstand low temperatures of -45 ℃, high temperatures of+150 ℃, as well as harsh environments such as humidity, salt spray, and chemical corrosion, adapting to the needs of different climate regions.
Application scenarios
High voltage system for new energy vehicles
Applied in battery packs, power distribution units (PDUs), on-board chargers (OBCs), and DC/DC converters for pure electric and hybrid vehicles, serving as the core structural components for high-voltage interconnection. The epoxy powder coating provides a 5000 VDC withstand voltage capability, and the thin layer insulation (150-300 μ m) can adapt to millimeter level gaps between battery cells, while meeting the reliability requirements.
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Photovoltaic energy storage and new energy generation system
Busbar insulation coating powder is used for internal electrical connections of photovoltaic inverters, energy storage battery clusters, and industrial and commercial energy storage cabinets. Powder coating has excellent resistance to humidity, salt spray, and high temperature and humidity environments. It has passed the double 85 (85 ℃/85% RH) test for more than 1000 hours, and the insulation resistance is stable>100 M Ω.
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Rail Transit and Power Distribution System
Epoxy power coating insulated busbars are applied to the main and branch busbars of auxiliary converters, traction converters, and medium and low voltage distribution cabinets in rail transit. Epoxy powder coating provides reliable interphase insulation to prevent short circuit faults, while its rigid structure can withstand mechanical impacts and wide temperature range changes during vehicle operation, enhancing the overall safety redundancy of the system.
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Data Center UPS and Industrial Power Electronics
Copper busbar powder coating is applied to high current transmission busbars inside data center uninterruptible power supplies (UPS), industrial frequency converters, and high-power power supplies. The high-purity copper substrate (conductivity ≥ 97% IACS) ensures low resistance (≤ 0.00001 Ω) and low temperature rise. The powder coating achieves efficient insulation in a compact space, supporting high power density design.
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contact us
Xiamen Apollo Stamping Welding Technology Co., Ltd is a professional service provider for new energy metal processing solutions. We can help you accurately match your needs and maintain the bottom line of device safety. Welcome to consult us.
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