PVC Dipped Insulated BusBar
PVC Dipped Insulated BusBar is designed for flexible power connections requiring electrical isolation. Its process includes copper pretreatment, PVC dipping, thermal curing, precision machining, and 100% inspection. Integrated CNC, laser cutting, welding, tooling, and testing support custom production from drawings. Free samples are available in 1–2 days, new-tool samples in 20–30 days, and batch orders in 15–20 days, under ISO 9001:2015 and IATF 16949.
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Product Introduction
What is a PVC Dipped Insulated BusBar?
PVC Dipped Insulated BusBar is a flexible copper bar manufactured by applying PVC insulation directly onto a T2 copper soft connection through a controlled dipping process. The copper bar serves as the current-carrying conductor, while the PVC dipping layer electrically isolates the specified sections of the conductor. This structure combines copper conductivity, flexible connection capability, and integrated insulation protection in a single busbar component.
Production process of PVC Coated Bus Bars
Conductor Pretreatment: The Insulated Custom Copper BusBar with PVC Dipping conductor undergoes automated degreasing, derusting, passivation, and drying to form a uniform passivation layer, improving the adhesion of the insulation layer, eliminating bubbles in the PVC coating, and eliminating defective products through online inspection, ensuring the basic quality of the product.
Preheating Treatment: The pretreated Dipped Insulated BusBar conductor is placed in a constant temperature oven (120-150℃). The preheating time is precisely controlled according to the cross-section to ensure uniform temperature, laying a solid foundation for subsequent PVC coating and curing, and preventing loose adhesion of the insulation layer.
PVC Coating: The busbar uses automated equipment to immerse the conductor in the treated liquid PVC impregnation solution. The speed and depth are precisely controlled to ensure uniform insulation layer thickness and a smooth surface, with uniformity improved by more than 40% compared to traditional processes.
Curing and Molding: The coated busbar is placed in a constant temperature oven (160-180℃) for segmented curing for 10-20 minutes to ensure full curing of the PVC insulation layer, improving its mechanical strength and weather resistance, and preventing cracking and performance degradation.
Precision Machining: Based on customized requirements, CNC machining and laser cutting processes are used to process the Plastic Dipping Copper Busbar conductors, with dimensional tolerances ≤ ±0.05mm and welded joint contact resistance < 5μΩ, ensuring product compatibility and conductivity stability.
Finished Product Inspection: Each batch of products undergoes 100% full-item testing, with data recorded using precision instruments and reports issued. Each Copper Busbar meets engineering selection standards, and samples are retained and sealed for five years for after-sales traceability.
Customization process of PVC Insulated Copper Busbar
Demand Matching and Assessment: The customer provides drawings specifying their customization requirements, such as conductor cross-section and insulation thickness. Our company assesses the feasibility, cost, and delivery time of the proposed solution based on the product's process and material characteristics, providing optimization suggestions to ensure the Busbar Isolation is suitable for the customer's operating conditions.
Sample Order Confirmation: After the solution and price are confirmed, the customer places a sample order and prepays 50% of the mold fee. Our company, utilizing its own mold workshop, initiates the production of customized molds for the Dip Insulated Busbar, ensuring the mold precision meets the product's dimensional requirements (tolerance ≤ ±0.05mm).
Sample Production and Testing: After the mold is completed, our company produces 1-20 samples free of charge according to the busbar's core process, which are then sent to the customer for testing via express delivery. A test report is provided simultaneously to verify the product's dimensions, performance, and installation compatibility.
Mass Production Commencement: After the samples pass testing, the customer pays the remaining mold fee and places a mass order, prepaying 30% of the payment. Our company mass-produces according to ISO standards, strictly controlling parameters such as the product's insulation layer and dimensions, with a delivery time controlled within 15-20 days.
Product delivery and traceability: After the products are mass-produced, they are 100% tested, a report is issued and a packaging list is submitted. After the customer pays the balance, the products are delivered in standardized packaging according to the busbar size. Samples of each batch of products are retained and sealed for five years for easy traceability.
Main functions of PVC Dipping Cover Copper Busbar
High-efficiency conductivity
Utilizing high-purity copper conductors, the PVC Dipped Insulated BusBar achieves high-current, low-loss transmission, meeting the current-carrying requirements of high-power equipment in new energy and power electronics fields, reducing energy loss, and improving power system operating efficiency.
01
Reliable insulation
The busbar uses a one-piece molded PVC insulation layer with excellent insulation performance, eliminating leakage and short-circuit hazards. The seamless design avoids insulation failure, making it suitable for high-voltage, high-power scenarios and avoiding insulation aging problems caused by long-term overload.
02
Corrosion and moisture resistance
The PVC insulation layer is tightly bonded to the copper conductor, forming a sealed protective system that isolates air, moisture, and chemical media, preventing oxidation and corrosion of the copper conductor, extending product lifespan and equipment maintenance cycle.
03
Easy installation
The Busbar Isolation supports customized processing, allowing flexible adjustment of size and bending angle, compatibility with various welding processes, and a phase sequence color code design, simplifying the installation process, facilitating phase sequence identification, and reducing installation error rates.
04
Frequently Asked Questions about Plastic Dipping Copper Busbar
Q: What is the production process for PVC Dipped Insulated Busbar?
A: The process includes conductor pretreatment, preheating, PVC dipping, curing, precision machining, and finished-product inspection. Process parameters are controlled at each stage to maintain consistent insulation coverage, dimensional accuracy, and electrical connection quality.
Q: How is PVC insulation applied to the copper busbar?
A: The copper conductor is pretreated and preheated before being immersed in a PVC impregnation solution using controlled dipping speed and depth. The coated busbar is then cured in a temperature-controlled oven to form the finished insulation layer.
Q: Can the PVC Insulated Copper Busbar be customized to customer drawings?
A: Yes. Customization can cover conductor dimensions, insulation thickness, bending angle, connection holes, exposed conductive areas, and overall geometry. CNC machining, laser cutting, and dedicated tooling can be selected according to the required production volume and structure.
Q: How is the quality of PVC Coated Bus Bars inspected?
A: Finished products undergo 100% inspection according to the defined quality requirements. Dimensional data, insulation-related characteristics, and electrical performance can be recorded, with inspection reports and retained samples supporting batch traceability.
Q: What are the main functions of a PVC Dipping Cover Copper Busbar?
A: It provides electrical conduction, insulation protection, moisture and corrosion protection, and easier installation. The PVC layer isolates the designated copper surfaces, while the flexible copper structure supports customized bending and connection configurations.
Contact Us
If you have any questions about the procurement, selection, or other aspects of PVC Insulated Copper Busbar, please feel free to contact us. Our professional team provides technical support, cost reduction assistance, and sample support to help your project get off to a successful completion.
PVC Dipped Insulated BusBar uses T2 copper, with an 80–120 μm PVC insulation layer applied through a controlled dipping process. Key specifications include custom dimensions, bending configurations, connection holes, exposed copper areas, and insulation coverage according to customer drawings.
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