Copper Busbar PVC Insulated
The Copper Busbar PVC Insulated is an integrated electrical energy transmission component. It consists of conductive busbars (copper bars/aluminum bars), polyethylene (PE) heat shrink insulation tubes, and supporting connection components (bolts, terminals, insulation gaskets, etc.). Its core function is to transmit high current (100A-3000A) and high voltage (1kV-35kV). At the same time, through the tight coating of PE heat shrink tubes, it isolates the Battery Terminal Bus Bar from moisture, dust, metal impurities, and adjacent conductors in the external environment. It prevents safety accidents like electric leakage, partial discharge, and phase-to-phase short circuits. It ensures the long-term stable operation of power systems under complex working conditions (such as high temperature, humidity, and vibration).
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Product Introduction
Products Description
In fields like power transmission, new energy, and industrial control, busbars are core carriers for electrical energy transmission. Their insulation performance directly determines the safety, stability, and operating efficiency of the entire system. The Copper Busbar PVC Insulated uses polyethylene (PE) heat shrink tubes as the core insulation layer, combined with high-conductivity busbar base materials. It creates an electrical energy transmission component with excellent insulation performance, low transmission loss, and strong environmental adaptability. This product is customized for high-voltage and high-current transmission scenarios in different industries. It can effectively solve problems of traditional bare busbars, such as easy short circuits and fast insulation aging. It provides reliable insulation and conduction solutions for various power systems.
Material Advantages
(I) Conductive Busbar Materials
- Base Material Selection: Mainstream models use T2 red copper or 6061 aluminum alloy. T2 red copper has a conductivity of 98% (IACS), much higher than ordinary brass (70% IACS), greatly reducing resistance loss and busbar heating. 6061 aluminum alloy, with a density of 1/3 that of copper, is lightweight and low-cost, with 61% IACS conductivity.
- Surface Treatment Process: Busbar surfaces get tin plating (5μm-12μm) or silver plating (1μm-5μm). Tin-plated layers resist corrosion (no rust in 500h salt spray tests), preventing oxidation in humid/high-salt areas (coastal regions, chemical workshops) and extending service life to over 15 years. Silver-plated layers have 99.9% IACS conductivity and ≤3mΩ contact resistance, fitting high-frequency/high-current scenarios (medium-frequency induction heating) to reduce contact loss and boost transmission efficiency.
- Mechanical Performance Guarantee: T2 red copper busbars have ≥220MPa tensile strength and ≥35% elongation. 6061 aluminum alloy busbars have ≥180MPa tensile strength and ≥15% elongation. Both withstand vibration (10Hz-2000Hz, 100m/s² acceleration) and impact (500m/s² acceleration) during operation, avoiding deformation or fracture to keep the conductive path stable.
(II) PE Heat Shrink Tube Materials
- Base Material Characteristics: Modified cross-linked polyethylene (XLPE) is the core raw material. Radiation cross-linking forms a 3D network structure, greatly improving insulation, temperature resistance, and aging resistance compared to ordinary PE.
- Flame Retardant Performance: 30%-40% environmental magnesium hydroxide flame retardant is added, reaching UL94 V-0 grade. It self-extinguishes within 30s when on fire (no drips), meeting power system fire safety needs and reducing fire spread risks.
(III) Supporting Component Materials
- Bolts and Nuts: Made of 316 stainless steel, with ≥580MPa tensile strength and no rust in 1000h salt spray tests. They suit high-corrosion environments (coastal areas, chemical industry), prevent loose connections from rust, and ensure reliable busbar-equipment connection (≤5% tightening torque deviation).
- Insulation Gaskets: Made of high-temperature resistant PTFE, with a -200℃ to 260℃ temperature range and ≥10¹⁵Ω insulation resistance. They prevent bolt-busbar leakage and have excellent corrosion resistance, fitting high-voltage/high-temperature scenarios.
Application Scenarios
Power System
- Distribution Transformer: Used to connect the transformer's low-voltage (0.4kV) busbar to the low-voltage cabinet.
- High and Low Voltage Cabinets: Connects main and branch busbars inside cabinets. Full-dimensional insulation eliminates inter-busbar discharge risks.
New Energy Field
- Photovoltaic Inverter: Connects the inverter's DC (600V-1500V) and AC (380V-10kV) busbars.
- Energy Storage System: Connects energy storage battery pack modules and PCS to the battery pack. High insulation prevents electrolyte leakage-caused insulation failure.
Rail Transit
- High-Speed Railway Auxiliary Power System: Connects busbars in auxiliary power cabinets. Modular design fits compact high-speed rail equipment space. Low loss reduces energy waste and improves energy efficiency.
Industrial Control
- Medium-Frequency Induction Heating Equipment: Connects the equipment's high-frequency (500Hz-10kHz) busbars. Silver-plated busbars and terminals (≤3mΩ contact resistance) cut high-frequency transmission loss. The PE heat shrink tube's high insulation prevents high-frequency interference, ensuring heating efficiency and stability.
why Choose us
The safe operation of the power system is inseparable from reliable insulation protection. With its excellent product characteristics, scientific working principle and stable insulation effect, the heat shrink tube insulated busbar has become an ideal choice for the insulation solution of the modern power system. If you are troubled by the busbar insulation problem or have the demand for purchasing The Copper Busbar PVC Insulated, please feel free to contact us - XIAMEN APOLLO will provide you with professional technical consultation and customized solutions to jointly protect the safety and stability of the power system!
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