Copper Busbars With Epoxy Powder Insulation
Copper busbars with epoxy powder insulation are high-performance electrical connection components widely used in high-power power electronic systems such as new energy vehicle battery packs, thin-film capacitors, photovoltaic energy storage systems, distribution cabinets, and rail transit. The product is made of high-purity copper as the substrate, and a uniform, dense, and high dielectric strength insulation layer is formed on the surface by spraying epoxy powder, which combines excellent conductivity and reliable electrical safety protection.
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Product Introduction
In today's rapidly developing new energy technology, the safety and efficiency of the power system have become key challenges. Our Copper busbars with epoxy powder insulation are designed to solve electrical connection problems in high voltage and high current environments. As the core component of power transmission, this product provides stable and reliable power transmission guarantees for equipment in fields such as electric vehicles, photovoltaic energy storage, and industrial distribution through precise manufacturing processes and high-quality material selection.
Manufacturing Advantages
Capacity and delivery capability
The monthly production capacity of Copper busbars with epoxy powder insulation reaches 50 million pieces, and the flexible production line supports seamless switching between small batch (MOQ 1,000pcs/item) and large batch modes. Standard orders can be delivered within 7-10 days, while sample orders can be completed within 10-20 days (including tooling/mold development). Provide 1-10 free samples to reduce customer selection risks.
Process Capability Matrix
Our copper busbar manufacturing process adheres to strict precision standards, with stamping accuracy controlled within ± 0.05mm, bending angle tolerance maintained at ± 0.5 °, and welding tension reaching no less than 80% of the base material to ensure structural stability; the surface treatment coating thickness is controllable between 3-12 μ m with a uniformity error of ± 10%, while for the Epoxy powder coating insulated busbar, the insulation coating thickness accuracy is ± 0.05mm.
Quality assurance system
Our products have obtained authoritative certifications including ISO9001, IATF16949, RoHS and REACH, supported by full-chain production traceability covering raw material furnace number, plating solution batch, coating process parameters and finished product serial number, and each Insulated coating busbar undergoes strict performance tests including conductivity, temperature rise, bending, voltage resistance, salt spray and flame retardancy to ensure stable and reliable quality for global engineering applications.
Design advantages
Strong adaptability to irregular structures
The Epoxy powder spraying process can uniformly cover all concave convex and corner areas, ensuring that the insulation layer has no dead corners or weak points on complex geometric structures.
Partial insulation optional
This selective insulation design enables the same Powder coated busbar to meet high-voltage isolation requirements while ensuring reliable electrical contact in the grounding or welding area.
Integrated assembly design
By pre installing PEM nuts, bolts, or brackets, Busbar coating with epoxy coating powder has direct assembly capability upon arrival at the customer's production line, without the need for secondary processing.
Compatible with multiple welding processes
The surface state of the bare copper area is stable and there is no residual insulation layer, which can seamlessly adapt to mainstream welding equipment without the need for customers.
Quality assurance system
Copper busbars with epoxy powder insulation have passed ISO9001, IATF16949, RoHS, and REACH international certifications, meeting the stringent standards of the automotive industry. Establish a full chain traceability system for raw material furnace number, plating solution batch, coating parameters, and finished product serial number, with complete data archiving. Equipped with a complete set of testing capabilities including conductivity, temperature rise, bending, insulation withstand voltage, salt spray, and flame retardancy, to ensure reliable product quality.
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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