Heat Shrink Tube Copper Insulated Busbar
Our Heat Shrink Tube Copper Insulated Busbar is composed of a high-conductivity copper conductor and a radiation-crosslinked polyolefin heat-shrink insulation layer. It is a core current-carrying component for the collection, distribution and transmission of electrical energy in new energy and power electronic systems.
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Product Introduction
Heat Shrink Tube Copper Insulated Busbar are conductive busbar structures made of highly conductive copper as the base material, formed by stamping/bending/welding, and then coated with a cross-linked polyolefin or fluoropolymer heat-shrinkable insulation layer on the outer surface. Their core function is to achieve a structural integration of low-impedance conductive path and reliable electrical insulation in high-current-density transmission scenarios.
In new energy storage, power electronic converters, and high-power power distribution systems, this type of busbar typically serves as a key carrier for energy transmission and electrical connection between modules, undertaking comprehensive functions of current distribution, system isolation, and safety protection.
Standardized production process
Copper Stress Relief Pretreatment: T2 oxygen-free copper busbars are rolled using a quadruple rolling mill, followed by constant-temperature annealing to eliminate internal stress in the substrate. Edges are CNC rounded with a radius of curvature (R≥0.8mm). Upon arrival, metallographic and conductivity tests are conducted to ensure compliance before PVC Heat Shrinkable Sleeves For Busbar transfer, mitigating issues such as tip discharge and load deformation.
Copper Corrosion Protection Interface Treatment: Automated pickling and passivation combined with tin/silver plating provides protection. The plating tolerance is ±0.02mm, optimizing interface adhesion, resisting condensation and salt spray corrosion, and stabilizing conductive contact resistance for Insulated Flexible Busbar With PVC Insulation.
Sleeve Alignment and Insertion: Dedicated positioning fixtures center the heat-shrinkable tubing during insertion, ensuring a coaxiality deviation ≤0.08mm. This eliminates issues such as tubing eccentricity and uneven wall thickness, mitigating the risk of insulation breakdown under high-voltage conditions for Heat Shrinkable Busbar Insulating Tape.
Negative Pressure Closed-Loop Heat Shrink Coating: Infrared temperature difference preheating combined with tunnel negative pressure heat shrinking removes air from the interface, achieving cavity-free composite molding. The longitudinal shrinkage rate is ≤5%, ensuring Heat Shrink Tube Insulation Copper Busbar consistent insulation coating dimensions.
Precision machining for aging and shaping: Maintaining a constant temperature of 80℃ for 2 hours releases internal stress within the Heat Shrink Sleeve Insulated Copper Busbar coating, preventing later shrinkage and delamination; integrated CNC bending and drilling ensures standardized bars assembly tolerances and adaptability to automated assembly operations.
Electrical testing and traceability packaging: Each Flat Copper Battery Busbar with Heat Shrink Tube undergoes withstand voltage and partial discharge non-destructive testing; qualified products are laser-marked for traceability; graded, light-proof packaging is provided, along with quality inspection reports, meeting the bars acceptance standards for centralized procurement and overseas projects.
Project details
Interface Details
The insulation layer is free of bubbles, particulate impurities, and interface gaps upon dissection; the copper surface is free of oxidation spots; the interlayer adhesion is ≥50N; and there is no residue after peeling for Copper Flat Square Busbars with PVC Heat-Shrink.
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Wall Thickness Details
The Copper Busbar with Heat Shrink Tube Insulation uses a uniform wall thickness molding process throughout; the insulation layer at the ends and bends shows no stretching or thinning; the insulation on the outer side of the bend shows no whitening or micro-cracks.
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Process Details
Laser marking is abrasion-resistant and colorfast; there is no insulation chipping at openings; the Pure Solid Copper Busbar with Heat Shrink Tubing ends are tightly sealed without gaps.
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Testing Details
Each unit comes with an electrical testing receipt; each batch comes with a metallographic report, withstand voltage report, and salt spray aging report; third-party re-inspection and verification of Heat Shrink Tube Copper Busbar Connection quality are supported.
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FAQ
Q: In condensation conditions, does the insulation layer of the energy storage cabinet absorb water and reduce resistance?
A: The Copper Busbars PVC Heat-Shrink Insulation Sleeves uses a negative pressure, cavity-free encapsulation + end-sealing process. The water absorption rate of the insulation material is ≤0.05%, preventing water vapor penetration. The insulation resistance remains stable under condensation conditions, with no whitening or deterioration.
Q: Can the tolerances of batch-supplied products be adapted to automated production lines for cabinets?
A: The Insulated Heat Shrink Copper Connector Busbars is CNC-machined, with consistent bending and hole diameter tolerances across batches. No on-site grinding is required, allowing direct adaptation to automated robotic assembly operations.
Q: During high-frequency switching, does the insulation layer bulge or delaminate?
A: The Heat Shrink Tube Copper Insulated Busbar undergoes aging stress relief treatment, resulting in a stable, glue-free structure. After alternating current fatigue testing, no delamination, bulging, or delamination issues were observed under high-temperature current-carrying conditions.
Q: Does the Heat Shrink Tube Insulation Copper Busbar support traceability and third-party electrical re-inspection?
A: Single laser traceability coding, batch comes with a complete set of quality inspection reports, the product's electrical parameters are stable, and it can be sent to a third-party laboratory for retesting and verification at any time.
Contact Us
For inquiries regarding operating condition selection and verification, sample application, bulk supply, and non-standard customization, please feel free to contact our engineering team to customize a full-cycle supply solution for your project that is compatible with the Heat Shrink Tube Copper Insulated Busbar.
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