PVC Dipped Insulated BusBar
PVC Dipped Insulated BusBar are integrated conductive components that form a continuous insulation layer on the surface of copper busbars through an impregnation process. They are suitable for new energy and power electronic systems with high requirements for electrical safety, structural stability and long-term reliability.
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Product Introduction
PVC Dipped Insulated BusBar are integrated insulating and conductive components specifically designed for the new energy and power electronics fields. Using high-purity copper as the conductor, a hot-dip plastic coating process tightly bonds the PVC insulation layer to the conductor, balancing both conductivity and insulation performance. The product focuses on core requirements such as high-current transmission and adaptability to complex environments in engineering scenarios. It is compatible with various power electronic devices, including new energy power plants and power battery packs, adhering to engineering-grade standards. It is the preferred solution in engineering procurement, balancing performance, cost, and reliability, and meets the selection requirements of system engineers for technical compatibility and long-term reliability.
Production process
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 Soft Connection Copper Busbar meets engineering selection standards, and samples are retained and sealed for five years for after-sales traceability.
Customization process
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
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
Q: WHAT ARE YOUR CERTIFICATES?
A: We have ISO9001, IATF 16949 certificates, RoHS and Reach.
Q: DO YOU ACCEPT OEM?
A: Yes. All busbar size can be customized. Logo can be made as your request.
Q: CAN YOU PROVIDE SAMPLES?
A: Yes, but the Dipped Insulated BusBar sample fee and freight will be paid by your company.
Q: HOW LONG CAN I GET A QUOTATION?
A: After you send us Busbar Isolation drawing (including material), we can give you the quotation within 1 DAYS.
Q: WHY CHOOSE OUR PVC Dipped Insulated BusBar?
A: We are the original factory in China, can supply the Ex-works;
We have been in professional in new energy field 15 years more and have enough successfull experiences to help you improve technology but cost down;
We have branches sales office in India, Iran, Spain, Germany, Japan, can supply the fast local service.
Contact Us
If you have any questions about the procurement, selection, or other aspects of PVC Dipped Insulated 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.
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