Insulated Copper Bus Bar Epoxy Coated
In modern data centers, UPS uninterruptible power supply systems, server racks, power conversion equipment, and industrial power distribution systems, the stability, security, and space utilization of current transmission are becoming crucial considerations in equipment design. Compared to traditional cable connections, Insulated Copper Bus Bar Epoxy Coated (ICOB) is becoming an important component of next-generation high-power power supply systems due to its higher current-carrying capacity, superior insulation protection performance, and more compact structural design. Apollo's ICOB uses high-conductivity copper as the conductor substrate. Through precision molding and epoxy powder electrostatic spraying, a uniform and dense insulation layer is formed on the conductor surface, achieving not only safe and reliable electrical isolation but also effectively improving the product's corrosion resistance, environmental adaptability, and long-term operational stability.
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Product Introduction
Insulated Copper Bus Bar Epoxy Coateds are conductive connection components that use highly conductive copper busbars as the main body, with an insulating protective layer formed through an epoxy resin powder coating process.
Compared to traditional PVC tubing, heat-shrink tubing, or insulating tape, the epoxy powder coating can directly adhere to the copper busbar surface, forming a continuous and uniform insulation layer. This allows the busbar to achieve a higher level of insulation protection while maintaining excellent conductivity.
This structure not only reduces the risk of system short circuits but also enables a more compact busbar layout, providing more possibilities for optimizing internal equipment space.
Key Functions
High-Efficiency High-Current Transmission
Enables low-loss power connections between UPS input/output terminals and server power distribution units.
01
Comprehensive Electrical Isolation
Provides reliable insulation protection against short circuits, leakage current, and accidental contact, enhancing system safety.
02
Structural Support and Fixation
Combines conductor and mechanical support functions, simplifying cabling design and reducing the use of traditional cables.
03
Environmental Isolation Protection
Blocks dust, moisture, and chemical corrosion, ensuring long-term stable operation in a clean data center environment.
04
Enhanced System Reliability
Epoxy Powder Coating Custom Copper Busbar supports rapid installation and maintenance, reducing downtime and helping data centers achieve high availability goals.
05
Design Advantages: Customized Freedom for High-Density Power Supplies
| Unrestricted Shape Complexity | Epoxy coating can cover L-shaped, U-shaped, Z-shaped, three-dimensional twisted, and even branched Customized Powder Coated Bus Bars. The only limitation is the inability to coat enclosed cavities (such as square shapes), but this can be achieved with a modular design. |
| Selective Insulation Design | Through precise masking, a composite structure of "partial bare copper (for bonding or grounding), partial thin insulation (for heat dissipation areas), and partial thick insulation (for high-voltage areas)" can be achieved on a single copper busbar. This design is very common in high-end server power supplies. |
| Ultra-Thin Edge Design | For Copper Bus Bar Epoxy Powder Coating for Power Distributions requiring multi-layer stacking, the coating thickness can be controlled to around 150μm, making the total thickness almost equal to the stacked bare copper busbars, meeting the stringent height restrictions of 1U power supplies. |
| Integrated Marking | Laser marking is directly engraved on the cured coating to a depth of approximately 20–30μm, without damaging insulation performance, and the markings are permanent. |
| Pre-assembly installation | Press-fit nuts, welding studs, or thermal pads can be pre-installed according to drawings, and the coating automatically covers non-working surfaces. |
Product Features and Technical Characteristics
Superior Conductivity and Low Impedance: High-purity copper conductors ensure extremely low resistivity, enabling efficient current transmission, reducing heat loss and voltage drop, and improving system energy efficiency.
High-Performance Epoxy Coating: The coating has uniform thickness and a dense surface, exhibiting excellent dielectric strength and arc resistance, significantly reducing the risk of creepage and flashover.
Enhanced Mechanical Protection: The coating has high hardness, is wear-resistant, and impact-resistant, effectively resisting mechanical stress during installation and long-term vibration.
Excellent Environmental Adaptability: Resistant to high temperatures, humidity, and chemical corrosion, suitable for the constant temperature and humidity environment of computer rooms, while also possessing good flame retardant and low-smoke properties, meeting stringent fire protection and safety regulations.
Flexible Customization Capabilities: Insulated Copper Bus Bar Epoxy Coated Supports complex bending, multi-angle forming, precise hole layout, and partially exposed terminal design, meeting the space constraints and interface requirements of different cabinets and power systems.
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In addition to providing high-quality Epoxy and Powder Coated Neutral Copper Busbar products, we can also provide customized bus engineering solutions based on your current rating, installation space, temperature rise requirements, and system architecture, helping projects complete design verification faster and smoothly enter the mass delivery stage.
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