Heat Shrink Tube Copper Busbar Connection
As new energy vehicles, energy storage systems, charging equipment, and industrial power electronic equipment develop towards higher voltage and higher power density, traditional bare copper busbars can no longer meet the comprehensive requirements of systems for insulation safety, space utilization, and long-term reliability. Heat Shrink Tube Copper Busbar Connection is an insulated busbar solution that combines a high-conductivity copper busbar with a high-performance heat-shrinkable insulating sleeve. The product is manufactured through copper busbar stamping, bending, surface treatment, and heat-shrinkable insulation coating processes. While maintaining excellent conductivity, it achieves overall insulation protection for the busbar, significantly improving the safety and integration of the electrical system.
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Product Introduction
Heat Shrink Tube Copper Busbar Connections are essentially high-voltage power connectors that use a copper busbar as the core conductor, with the copper busbar fully encased in a heat-shrinkable insulating sleeve.
The product typically consists of the following components:
T2 copper conductor
Tin-plated copper busbar
Precision stamping structure
Custom bending structure
Heat-shrink insulating sleeve
Mounting connection holes
Through a heat-shrinking process, the insulation layer is tightly bonded to the copper busbar, forming an integrated connection solution that combines conductivity and insulation.
For modern new energy equipment, this structure effectively reduces installation space requirements while improving the overall system safety level.
Extensive Application Advantages: Empowering Heavy-Duty, Long-Life Electrical Ecosystems
Data Center Precision Switchgear and Medium-Low Voltage Intelligent Switchgear (GI/AIS)
Providing ultra-thin, safe, high-density, zero-partial-discharge Customized Copper Busbar Connection with Heat Shrink Tubing connections within a compact space.
High-Power Wind Power Converters and Photovoltaic Containerized Substations
Coping with the high salt spray and high humidity environments of offshore wind power, and the extreme temperature fluctuations of photovoltaic power plants day and night, heat-shrink tubing tightly wraps the Copper Busbar with Orange Heat Shrink Tubes, providing excellent physical moisture protection and resistance to chemical and electrochemical corrosion.
Rail Transit Locomotive Traction Powertrain
Withstanding the high-frequency and intense mechanical vibrations and impacts of frequent starting, acceleration, and braking of locomotives, the tubing remains undeformed, cracked, and does not loosen.
Design Advantages: Geometry of Topology, Routing, and Stress Relief
| Deburring and Electric Field Rounding Design | In rigid sleeve connections, we do not allow any burrs larger than 0.2mm. During the design phase, all punched and cut edges must be mechanically chamfered and deburred to prevent sharp edges from puncturing the heat shrink tubing or causing tip discharge under an electric field. |
| Thermal Expansion Displacement Compensation Structure | During alternating periods of extreme cold and heat, the copper substrate undergoes significant thermal expansion and contraction in rigid connections. We design flexible bends in long straight sections or critical connection points to absorb thermal stress and prevent fatigue fracture or detachment of the heat shrink tubing due to repeated expansion and contraction of the substrate. |
| Precise Reconstruction of Creepage Distance and Clearance | At bolted connections, by designing specific sleeve chamfers and clearance areas, combined with boss insulating covers, we precisely control the shortest path between live parts and grounded parts, ensuring maximum creepage distance within a limited space. |
The core production process includes
High-precision extrusion and multi-layer co-extrusion to ensure uniform wall thickness and material density;
Electron beam irradiation cross-linking process to improve the material's mechanical strength and heat shrinkage memory properties;
Precision slitting and end treatment to avoid burrs affecting shrinkage performance;
Surface marking and quality inspection, including shrinkage rate testing, electrical performance verification, and environmental aging resistance testing;
100% factory inspection to ensure that each Heat Shrink Tube Insulation Copper Busbar fits tightly and is defect-free after shrinkage.
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Whether it's a new energy battery pack, a high-voltage power distribution system, or an energy storage equipment project, our engineering team can provide a one-stop solution for Flat Copper Battery Busbar with Heat Shrink Tubes, from structural design and sample development to mass production, based on your current load, installation space, insulation class, and assembly requirements.
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