Copper Busbar With Heat Shrink Tube Insulation
Copper Busbar with Heat Shrink Tube Insulation are composite conductive components used in high-current power connection systems, manufactured by combining highly conductive copper busbars with heat-resistant, insulating heat-shrink tubing. Through processes involving machining, surface treatment, and insulation application, the product achieves the dual functions of efficient power transmission and safe electrical isolation. Compared to traditional bare copper busbars, this insulated version retains the material's excellent conductivity while mitigating the risk of phase-to-phase short circuits, enhancing installation safety, and reducing space requirements within electrical cabinets. Widely used in sectors such as new energy vehicles, high-voltage power distribution, energy storage systems, industrial electrical cabinets, variable frequency drive equipment, charging stations, photovoltaic inverters, and renewable energy power systems, these busbars serve as a vital component of modern, highly reliable power connection solutions.
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Product Introduction
Copper Busbar with Heat Shrink Tube Insulation are rigid, high-current conductive component. They utilize rolled copper bars as the conductive core, encased in an insulating sleeve applied via a heat-shrink process. While retaining the high current-carrying capacity and structural strength characteristic of rigid busbars, the product integrates electrical insulation, environmental protection, and phase identification functions. Unlike flexible connectors designed primarily to accommodate displacement, this product is engineered for structured, backbone power transmission in fixed installations; it serves the dual purpose of conducting current and providing structural support, making it ideal for fixed power distribution backbones and rigid inter-module connections.
The product's core features are defined by four key characteristics:
A rigid, integrated structure. The core consists of solid rolled copper, offering high mechanical strength; it allows for long-span installation and can withstand external loads without the need for closely spaced insulating supports, thereby simplifying the system architecture and saving space within the cabinet.
Material Advantages: Synergy Between Metallurgical Purity and Radiation-Crosslinked Networks
Superior system performance stems from rigorous control over the metallurgical quality of the copper substrate and the polymer topology of the insulation material:
Control of intrinsic purity in high-conductivity T2 copper: We utilize T2 copper with a copper content exceeding 99.95% as the conductor substrate. By strictly controlling impurities such as oxygen, lead, and bismuth, we not only ensure high electrical conductivity (IACS ≥ 100%) but also impart excellent cold-bending properties, preventing micro-tearing or stress cracking during complex 3D bending processes.
Dielectric strength of radiation-crosslinked polyolefin: The insulation layer employs a modified polyolefin material crosslinked via electron beam irradiation. The crosslinked network ensures the material neither melts nor flows at sustained high temperatures (e.g., 125°C or even 150°C) and provides a dielectric breakdown strength far superior to conventional insulation materials for Insulated Flexible Busbar With PVC Insulation. Even under long-term thermal and electrical aging, the material maintains exceptionally high volume and surface resistivity.
Molecular-level design for tracking resistance and flame retardancy: To address industrial environments characterized by high humidity and dust, the heat-shrink tubing formulation incorporates specialized flame retardants and anti-tracking additives. This enables the material to not only pass the UL224 VW-1 flame retardancy test but also resist tracking caused by surface contamination and moisture, thereby preventing the formation of conductive carbonized paths on the insulation surface.
Detail Showcase
Cross-section details
Displays the Flat Copper Battery Busbar with Heat Shrink Tube substrate, heat-shrink tubing thickness, and the tight-fitting encapsulation.
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Terminal processing samples
Close-ups of various hole configurations and plated surface finishes.
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Installation scenarios
Actual photos showing internal Copper Busbar with Heat Shrink Tube Insulation arrangement within switchgear, bending transitions, and integration with mounting brackets.
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Dielectric strength test demonstration
Shows the insulation layer's stable performance under high-voltage conditions.
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Packaging and shipping
Uses protective foam and reinforced wooden crates to prevent insulation damage during transit; supports bulk container shipping.
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Application Advantage: Cost optimization across the entire lifecycle
High installation tolerance
Unlike rigid insulation sleeves, heat-shrink tubing accommodates slight positional deviations of the Copper Busbar with Tin Plated Heat Shrink Tubing during installation, simplifying the assembly process.
Resistance to vibration-induced loosening
In rail transit or heavy machinery applications, the strong adhesion of the tubing's inner wall prevents relative movement-and consequent abrasion-between the insulation layer and the conductor caused by vibration.
Rapid repair capability
If insulation damage is detected on-site, there is no need to replace the entire Copper Busbar Connector with Insulated Heat Shrink Tube section; simply cleaning the damaged area and applying a heat-shrink repair patch or wrap tape suffices, significantly enhancing equipment uptime.
contact us
If you are developing new energy vehicles, energy storage, power equipment, or industrial control systems, we can provide matching Heat Shrink Sleeve Insulated Copper Busbar solutions based on your electrical parameters, structural requirements, and application environment. Our professional manufacturing capabilities support the rapid implementation of projects and a long-term stable supply.
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