Insulated Copper Busbar With Heat Shrink Tube
The Insulated Copper Busbar with Heat Shrink Tube is a high-efficiency conductive connection component developed specifically for engineering applications in the fields of new energy and power electronics. It uses high-purity copper as the conductive core and is covered with a special heat-shrink insulating tubing. It combines excellent conductivity, reliable insulation protection, and convenient installation adaptability. It is mainly used in the internal power transmission and connection scenarios of equipment such as switchgear, inverters, transformers, and new energy battery packs.
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Product Introduction
This Insulated Copper Busbar with Heat Shrink Tube features a rectangular cross-section busbar made of high-purity electrolytic copper (≥99.95% Cu), covered with a double-walled cross-linked polyolefin heat-shrink tubing conforming to UL/IEC standards, forming an integrated structure of physical insulation and environmental protection. It is suitable for power electronic systems with stringent requirements for current density, temperature rise control, and long-term electrical contact reliability, such as new energy converters, energy storage systems, electric vehicle charging equipment, and industrial frequency converters.
Production process
Cutting
As the first core process in Heat Shrink Tube Polyolefin Busbar manufacturing, laser and CNC cutting technologies are used to precisely cut high-purity electrolytic copper. The entire process is automated and controlled, matching product specification tolerances to ensure a burr-free and deformation-free cut, laying a solid foundation for subsequent processes.
Punching
The cut copper material is precisely punched using specialized equipment, processing the required interfaces and holes as needed. Strict process standards are maintained to ensure the stamped structure matches the design, guaranteeing the continuity of conductivity and structural stability of the product interfaces, adapting to subsequent processes.
Bending
Using CNC bending technology, the stamped copper material is precisely bent according to the Heat Shrink Tubing BusBar's structural requirements. The bending angle and radius are controlled, and surface protection is applied to ensure the product is free of scratches and stress deformation after bending, guaranteeing the adhesion and insulation effect of subsequent heat-shrink wrapping.
Heat Shrink
The core process for product insulation protection. Using an intelligent production line, compliant heat shrink tubing is precisely fitted onto the bent copper busbar of the product. Heating parameters are strictly controlled to ensure that the heat shrink tubing fits tightly and without damage. The joints are sealed to ensure that the product meets insulation standards throughout the entire process.
Technology adaptability
Current and Voltage Adaptability
The PVC Insulation Busbar can flexibly adapt to cross-sectional areas of 10-1000 mm² according to engineering current carrying requirements, with resistivity controlled within standard ranges. The outer heat shrink tubing insulation voltage ranges from 1kV to 35kV, adapting to different power and voltage scenarios and widely applicable in new energy and industrial power distribution fields.
Customized Structure Adaptability
Leveraging precision machining capabilities, the product's copper busbars can be customized with various structures and adjusted bending radii. Interfaces can be customized as needed, perfectly adapting to confined internal spaces and accommodating both new projects and existing equipment upgrades.
Process and Interface Adaptability
The Busbar Sleeves Insulation is compatible with various mainstream connection processes and has strong compatibility with various electrical equipment interfaces, requiring no additional modifications. The heat shrink tubing can be printed with markings, improving installation and maintenance efficiency and reducing engineering selection and installation costs.
Customized service process
The client provides drawings in PDF/CAD/3D format, clearly defining their technical requirements for customized insulated copper busbars with heat shrink tubing. This includes core parameters such as the copper busbar cross-sectional area (10-1000mm²), length, structural shape (rectangular/irregular), heat shrink tubing specifications (insulation voltage 1kV-35kV, shrinkage ratio 2:1/3:1), and surface treatment (tin plating/silver plating, marking and printing).
Leveraging 30 years of experience in the electrical industry, we conduct a feasibility analysis and price assessment based on the client's customized needs and the core Busbar Insulating Tubing processes (cutting/punching/bending/heat shrinking). We then output a suitable customized solution, specifying the product material (99.9% high-purity electrolytic copper, cross-linked polyolefin heat shrink tubing) and its production compatibility.
After price confirmation, the customer places a sample order and prepays 50% of the mold fee. We then initiate custom mold Busbar Insulation Sheet. Upon mold completion, we produce 1-20 free samples according to the customized parameters (following ISO9001-2015 quality standards throughout). These samples are sent to the customer via express for conductivity, insulation, and dimensional accuracy testing. Once the samples pass inspection, the customer pays the remaining 50% of the mold fee.
The customer places a bulk order for the product and prepays 30%. Based on our production capacity and estimated delivery time (15-20 days), we initiate mass production, adhering to ISO9001-2015 and IATF16949 quality system standards throughout. We strictly control copper busbar dimensional tolerances and heat shrink tubing uniformity to ensure batch consistency and quality stability.
After mass production is completed, we provide a detailed packing list (indicating Heat Shrink BusBar specifications, quantity, and test report number), along with individual product inspection records. The customer pays the remaining 70% after verifying the information.
We will deliver goods to the address specified by the customer in accordance with the Customized Busbar Insulating Tube classification and packaging standards (dedicated packaging for small and large items), and provide localized after-sales technical support, including product installation and adaptation guidance, response to quality issues, and suggestions for later maintenance.
Why choose us
Leveraging 30 years of experience in the electrical industry and our comprehensive supply chain capabilities, we provide all-around reliable services for your procurement and selection of Insulated Copper Busbar with Heat Shrink Tube, precisely addressing procurement pain points and mitigating supply risks. As a group enterprise, we have an annual turnover of 200 million RMB, ample production capacity, and a bulk delivery time of 15-20 days, with free samples delivered in 1-2 days, significantly shortening project cycles. Our core technical backbone originates from Xiamen Hongfa Group, enabling us to provide qualified products that meet various international standards and cost-saving and efficiency-enhancing solutions tailored to your current-carrying capacity, insulation, and customized needs. We master the core production processes, maintaining full self-control throughout the entire process, strictly controlling product quality and batch consistency. Simultaneously, we leverage our supply chain advantages to achieve one-stop procurement, reducing collaborative costs. Our comprehensive global and localized service network, coupled with dedicated graded packaging, ensures safe cross-border transportation. Combined with high-standard quality certifications, we fundamentally guarantee the long-term reliability of our Copper Busbar PVC Insulated, allowing you to procure with peace of mind, select with confidence, and use with confidence.
Contact Us
If you have any needs regarding Insulated Copper Busbar with Heat Shrink Tube (selection, samples, customization, procurement), please feel free to contact us. Our professional team will respond quickly and provide suitable solutions to help your project be implemented efficiently.
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