5 Technologies of Insulation Layer Processes for New Energy Busbars

Since humans invented large current transmission, New Energy Busbars have been widely used in power, communication, energy storage and military industries. With the rise of new energy vehicles, Braided Copper Wires have gained more attention as excellent conductors for batteries and inverters.
Busbars can be divided by material into copper and aluminum. By stress release, they can be soft (copper or aluminum) or hard (copper or aluminum).

Both soft and hard busbars are used in new energy vehicles. Flexible busbars are also called laminated busbars. They are made by stacking many copper foils or sheets. After pressure welding, they form a connection part that is hard at both ends and soft in the middle. This soft part can bend and twist freely.
Unlike cables, new energy Flexible Braided Custom Connectors can have many shapes. Examples are L-shape, U-shape and long strip. Different bends let them fit vehicle shapes more closely and take less space. But because the structures are different, the choice of insulation layer also changes. Here are five ways to process the insulation layer of new energy busbars.

• Heat shrink tube processing: Polyolefin heat shrink tubes for new energy vehicle busbars (Hongshang Technology). This is a common method. It uses polyolefin heat shrink tubes to wrap the busbar. Then heat shrink equipment shrinks the tube into shape. This method is simple to operate. It can also adjust performance parameters to meet customer needs. It is good for Flex Connector with simple bends. After shrinking, the surface is clean and flat. The shrinkage is even. There is no burning, fading, bubbles, scratches or cracks. The bending areas have no wrinkles.

• Dip coating processing: This is a common method for irregular new energy Braided Flexible Busbars Customized. The development cycle is short. It usually takes 15 to 20 days from mold opening to sample. The mold only has a male mold. The material cost ranges from a few hundred to a few thousand. The surface is smooth. The color is bright. The insulation effect is good. But because of the process, the thickness tolerance may be larger. It is hard to control the thickness uniformity.

• Powder coating processing: This method uses epoxy insulating resin powder. The process is not affected by busbar size or shape. Even at bending points, there are no wrinkles or bubbles. The busbar keeps its stiffness and hardness. It also has anti-corrosion, wear resistance and high voltage resistance. The process is simple. The labor and equipment costs are low.

• Extrusion processing: This is a new product in recent years. It uses special extrusion equipment to form the insulation layer. Materials include PVC and PA12. The method is similar to making traditional copper cables. The advantages are fast speed and mass production. The wear resistance is better than powder coating. But the cost is higher. Multi-layer copper sheet extrusion Braided Flexible Busbars have higher current capacity than copper bars of the same area. They are good for electric vehicle batteries, energy storage batteries and high voltage power equipment.

• Injection molding processing: Some laminated busbars have special requirements. The insulation layer shape and material are limited. The above four methods cannot finish the product. Only injection molding can be used. This needs a mold for the product appearance. The insulation is formed in one step by injection equipment. Materials are wide. PVC, TPE, TPU and others can be used if the equipment supports them.

At present, XIAMEN APOLLO has an independent R&D team and advanced equipment. It follows market trends and customer needs. It has launched many new products with both performance and cost advantages. Examples are polyolefin heat shrink tubes for new energy vehicle busbars and double-wall heat shrink tubes for automotive wire harnesses. These Insulation Layer Processes for New Energy Busbars can keep connection parts stable and reliable in all kinds of environments for a long time. We look forward to cooperating with you!