Analysis of PVC Dipping Insulated Busbar Process and Industry Application

In the copper bar insulation treatment process system, immersion molding is a widely used mainstream technology. In the industry, dipping epoxy resin powder is commonly referred to as dipping powder, and the process of dipping liquid PVC adhesive is called dipping. This article focuses on the latter for a detailed analysis. PVC Dipping Insulated Busbar, as a mature form of insulation treatment, plays an important role in electrical systems, but its application scenarios differ significantly. It is more commonly used in energy storage systems and less commonly used in power battery packs. The core reason is closely related to process characteristics and scenario requirements.

Copper busbar dipping is essentially a treatment method that uniformly covers the surface of copper busbar with liquid adhesive insulation material through a specific process, forming a dense insulation protective layer. This process can significantly improve the insulation performance of copper bars and provide assurance for electrical connection safety. PVC Dipping Insulated Busbar is a general term for this type of treated copper bars.

At present, the mainstream process uses polyvinyl chloride (PVC) adhesive material, which is made by mixing PVC resin, plasticizer, stabilizer, filler, and other components, and is in a gel-like fluid state at room temperature. The materials used in PVC Coated Bus Bars have the advantages of low cost and excellent fluidity, making them suitable for mass industrial production. The temperature range can cover -40 ℃ to 125 ℃, and the insulation strength can reach 20-28kV/mm, fully meeting the basic insulation requirements of electrical fields such as power batteries and energy storage systems.

In the field of power batteries, the limited application of impregnated copper bars is mainly due to two factors: firstly, the power battery pack has extremely high requirements for space and lightweight, and impregnation will increase the thickness and weight of the copper bars, making it inconvenient to install in small spaces such as BDUs and modules, which is not conducive to improving energy density; Secondly, the battery generates a lot of heat during charging and discharging, and the insulation layer can hinder heat dissipation, which may lead to excessive local temperature rise and affect safety. Although the Insulated Flexible Copper Bus Bar for Power Battery Pack solves the problem of flexible connection, the heat dissipation shortcoming cannot be avoided.

The energy storage system is an advantageous application scenario for impregnated copper bars, with a fixed installation mode that has loose space and weight restrictions, and focuses more on stability and safety. The excellent insulation and corrosion resistance of impregnated copper bars can adapt to the humid and dusty environment of energy storage power stations. The high insulation performance of Dipping Busbar for Connection can reduce the risk of leakage and meet the high safety redundancy requirements of energy storage systems. In addition, Plastic Dipping Electric Copper Busbar Custom Made can customize parameters according to the requirements of energy storage devices, further enhancing adaptability.

The product after copper bar immersion has multiple advantages, with stable insulation performance that can withstand voltages of 3500V AC/DC and above, effectively preventing current leakage, which is also one of the core requirements of Busbar Isolation; At the same time, the coating has good uniformity, and with the help of the fluidity of PVC adhesive, it can adapt to copper bars with complex shapes. It has strong adhesion, peel strength ≥ 4N/cm, is not easy to peel off, and can adapt to working conditions such as vibration and environmental changes.

For scenarios that require flexible connections, the Soft Connection Copper Busbar, after immersion treatment, can retain a certain degree of flexibility while ensuring insulation performance. In addition, the temperature resistance level of the product covers -40 ℃ to 125 ℃, and the thickness of the insulation layer can be fine-tuned between 1-2mm on one side, which can resist moisture and dust erosion. It performs well in the 192-hour salt spray test under 5% NaCl solution and 35 ℃ conditions. The selection of PVC Dipping Insulated Busbar can be optimized based on the size and weight of the impregnated copper bars to enhance installation stability.