Insulated Custom Copper Bus Bar With PVC Dipping
Insulated Custom Copper Bus Bar with PVC Dipping use high-purity copper as the conductive substrate and form a complete insulation protective layer through an overall PVC impregnation process. They support high-current conductive connection busbar components that can be customized in terms of shape, aperture, and size. They are mainly used in low-voltage to medium-voltage power distribution, new energy battery modules, and internal busbar connection scenarios in electrical control cabinets to achieve safe and efficient power conduction and potential isolation.
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Product Introduction
The Insulated Custom Copper Bus Bar with PVC Dipping is a custom copper busbar used in power distribution, high-voltage systems, and electronic equipment. This busbar features an insulation layer formed by impregnation of the conductive copper surface with PVC, effectively isolating high-voltage conductors, preventing electrical short circuits, and enhancing the busbar's durability in complex environments.
Working principle
Current Conduction
The copper bus bar provides a low-impedance path. High-conductivity copper (≥101% IACS) results in extremely low DC resistance and controllable Joule heating. Current is distributed to multiple output terminals via the molded copper busbar.
Electrical Isolation
The PVC impregnation layer forms an insulating barrier, tightly adhering to the copper surface. The PVC Dipped Insulated Bus Bar's insulation layer is bubble-free, preventing partial discharge, flashover, and leakage.
Protection Mechanism
The PVC is flame-retardant (oxygen index >26%), softening and carbonizing upon overheating to delay failure. The impregnation layer seals and protects the copper surface, preventing corrosion and avoiding increased contact resistance for Plastic Dipping Copper Bus bar.
performance advantages
Low Resistance, High Efficiency Conductivity
Utilizing T2 oxygen-free copper with a purity ≥99.9%, resistivity ≤0.0172Ω·mm²/m, it meets temperature rise regulations for high-current operation. Its current-carrying capacity is over 30% higher than traditional cables, suitable for 100A-1500A requirements and ideal for low-voltage, long-distance bus bars. The surface can be tin-plated/silver-plated to reduce contact resistance and improve conductivity stability.
Integrated Dip-Coated Insulation
The Insulated Custom Copper Bus Bar with PVC Dipping features integrated electrical-grade PVC dip-coating. Insulation layer thickness is customizable from 0.8-2.0mm, ensuring strong adhesion, no defects, and insulation resistance ≥100MΩ. Suitable for low-voltage systems of 600V and below, it complies with IEC and UL standards. V0 flame retardant rating eliminates short-circuit and leakage hazards, enhancing electrical system safety.
Highly Customizable and Adaptable
Supports full-dimensional customization, allowing for size adjustments, customization of L/Z/U-shaped and other irregular structures and hole details to fit non-standard equipment spaces; precision cold-pressing ensures hole concentricity ≤0.05mm, eliminating the need for additional insulating sleeves and enabling direct installation, improving Soft Connection Copper Bus bar assembly efficiency and reducing labor costs.
High Cost-Effectiveness and Durability
The copper substrate boasts a tensile strength ≥205MPa, exhibiting strong stability and a service life exceeding 10 years; PVC dip coating technology ensures efficient mass production, with costs 20%-30% lower than epoxy spraying, making it suitable for bulk purchases; the insulation layer is moisture-resistant and dustproof, delaying copper oxidation and reducing PVC Coated Bus Bars maintenance frequency and costs.
Frequently Asked Questions
What is the maximum operating voltage that PVC-impregnated insulated copper busbars can withstand?
Standard finished products are suitable for low-voltage circuits up to AC and DC 600V, only applicable to low-voltage bus bar applications, and not for high-voltage power systems.
Can customized irregularly shaped PVC-impregnated copper bus bars achieve full insulation coverage without any blind spots?
Yes, the overall high-temperature impregnation process can completely cover bends, edges, and the area around holes, leaving only the butt joints exposed for conductivity; the rest is fully insulated.
What are the advantages of this copper bus bar compared to heat-shrinkable insulated copper busbars?
The integrated impregnation molding provides stronger integrity, reducing the likelihood of sleeve detachment or displacement during long-term use. Irregularly shaped structures offer better coverage, and large-scale customization results in lower costs.
Can you provide quick quotations and sample services based on drawings?
We support customers providing CAD dimension drawings and physical samples for parameter verification. We can quickly generate customized solutions and provide small-batch samples for engineering testing and verification.
Contact Us
For Insulated Custom Copper Bus Bar with PVC Dipping, detailed technical parameters, or sample services, please contact us. Our professional technical team will provide you with one-on-one selection guidance and customized solutions.
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