Copper bus epoxy resin powder coating process and insulating busbar technical description

 

Copper strip preparation: Use high-conductivity copper as the base material, and process it into the required shape through precision cutting, bending and drilling processes. Surface cleaning: Deeply clean the surface of the copper bus to thoroughly remove oil, attached dirt and burrs to ensure coating adhesion. Area protection: Use high-temperature resistant tape to cover areas that do not need to be coated to prevent powder from adhering. Preheating treatment: Preheat the copper bar to 200–260°C to enhance the bonding strength between the epoxy resin powder and the copper bar.

 

Powder coating: The preheated copper bar is immersed in a fluidized bed containing insulating powder. The immersion time is usually 1–2 seconds, and the coating thickness can reach 300–400µm. The thickness can be increased by extending the dipping time or increasing the number of times. This process is suitable for the production requirements of Insulated Copper Bus Bar. Removing Masking: Immediately after application, remove the protective heat-resistant tape. Post-curing treatment: According to the size of the workpiece and ambient temperature, post-curing is performed as necessary to ensure that the resin is fully cross-linked and cured.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Strong adhesion: The epoxy resin system contains polar groups such as active epoxy groups, hydroxyl groups and ether bonds. It has excellent adhesion to polar substrates such as metals, and the coating is tight and does not fall off. Uniform coating: Whether it is a straight or special-shaped copper bar, it can be coated evenly, with no wrinkles, bubbles or pinholes at the bends, and the surface is smooth without warping.

 

Excellent protective performance: The coating provides reliable insulation and protective performance to meet electrical safety requirements under various working conditions. This feature is especially critical in Busbar Insulation Paint applications. Optional post-plating treatment: According to the needs of use, tin plating, nickel plating or silver plating can be carried out after coating to improve the conductive contact performance.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

As a thermosetting polymer, epoxy resin has good mechanical strength and thermal stability. Typical properties include: tensile strength up to 100MPa, heat deformation temperature exceeding 150°C, and ability to withstand high-temperature operating environments; it is also chemically resistant and resistant to acid rain and industrial pollutants. In insulation applications, epoxy resin coatings can be sprayed or dipped to achieve uniform coverage, with typical thicknesses of 2–3mm, forming an air-gap-free insulating barrier. Under hot and humid conditions, its insulation resistance can reach 10¹³Ω·m, far exceeding the national standard requirements. Epoxy Powder Coated Busbar Insulation is widely used in various power distribution systems based on the above performance advantages.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The epoxy resin tubular busbar uses highly conductive copper or aluminum as the main conductor, and is covered with an epoxy resin insulating coating to form a seamless tubular structure. Epoxy resin has excellent dielectric strength (usually over 100kV/mm) and chemical resistance, which can effectively prevent the risk of arc discharge and short circuit. Its low water absorption (less than 0.5%) helps maintain insulation stability in humid environments. The tubular structure can achieve uniform electric field distribution and reduce partial discharge, and is suitable for high-voltage power transmission and distribution fields. Compared with traditional cables, epoxy resin tubular busbars have higher current carrying capacity (up to 5000A) and longer service life (more than 30 years on average). This technology also has good adaptability for scenarios with high requirements on insulation and durability, such as Electric Vehicle Busbar Coating.

 

 

Our company specializes in the production of Epoxy Spray Copper Bus Bar series products, covering complete manufacturing capabilities from copper bar powder coating, insulating busbars to electroplating processing. All products strictly comply with industry standards, and customized solutions with different insulation thicknesses, plating types and special-shaped busbars can be provided according to customer needs. If you need further information, please contact us for details.