Detailed explanation of heat shrinkable busbar tube technology

Heat-shrinkable busbar tube is a polyolefin-based material product specially used for insulation protection of substation busbars and high and low-voltage switch cabinet busbars. The product is closely adhered to the surface of the busbar through a heat shrinkage process to form a continuous and uniform solid insulation layer. Compared with traditional insulating paint or tape, heat-shrinkable busbar pipe can be installed quickly on site without complex curing waiting times and is not significantly affected by the humidity of the construction environment. Its core working principle is based on the "memory effect" of polymer materials: the polyolefin substrate is cross-linked by electron irradiation during the manufacturing process to obtain a three-dimensional network structure. When heated to above the glass transition temperature, external force is applied to expand and rapidly cool and shape; when reheated during use, the material returns to its pre-expansion size, thereby tightly wrapping the busbar. This feature makes heat-shrinkable busbar pipes particularly suitable for retrofit projects of already installed or complex busbar systems. For power distribution equipment that requires high-reliability insulation protection, Customized Busbar Insulating Tube can be customized and produced according to the specific cross-sectional shape and length of the busbar to ensure fit and insulation effect during on-site installation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Heat-shrinkable busbar tubes are divided into three types according to voltage levels: 1kV, 10kV, and 35kV, which correspond to the insulation requirements of electrical systems at different voltage levels. The continuous operating temperature range is -55°C to 105°C. This wide temperature range feature enables it to adapt to a variety of working environments from outdoor substations in cold areas to high-temperature sealed electrical cabinets. The shrinkage ratio is available in two specifications: 2:1 and 3:1. The former is suitable for standard wrapping of conventional busbars, while the latter is suitable for busbars or joints with a large width and thickness ratio to ensure sufficient shrinkage in the width direction of the busbar.

 

The minimum initial shrinkage temperature is 80℃ and the minimum complete shrinkage temperature is 120℃, which means that on-site construction can be completed using an industrial heat gun without the need for complex heating equipment. In terms of color, standard products are available in three colors: red, yellow, and green, which correspond to the A, B, and C phase sequence marks of three-phase AC power, making it easy for on-site installation personnel to quickly identify and check. In bulk procurement scenarios, Solid Insulation Tubing Busbar has become the preferred solution for high-voltage switchgear busbar systems that require extremely high insulation continuity due to its one-time molding and seamless structural features.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The core application scenarios of heat-shrinkable busbar tubes include busbar insulation protection in substations, busbar wrapping inside high and low-voltage switch cabinets, and phase isolation of busbar duct systems. At the functional level, this product can effectively shorten the distance between phases in the switch cabinet and make the equipment structure more compact, which is of great significance for adapting to the development trend of miniaturization of electrical equipment. In outdoor or semi-outdoor environments, heat-shrinkable busbar pipes can resist corrosion from chemicals such as acids, alkalis, and salts, and protect the busbar metal substrate from environmental erosion.

 

From the perspective of safe operation and maintenance, the dense insulation layer can prevent short-circuit accidents caused by mice, snakes and other small animals climbing and touching the busbar, and prevent accidental injuries caused by maintenance personnel accidentally entering the live gap. When insulating transformation of traditional switchgear with bare busbar design, heat-shrinkable busbar tubes provide a convenient solution to complete the construction without disassembling the busbar. In the field of new energy, busbars used in EV Battery Connectors systems also require reliable insulation protection, and heat shrink technology has gained application due to its installation flexibility and insulation reliability.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The on-site construction process of heat-shrinkable busbar pipe is relatively simple, but the key operation details directly affect the insulation effect. First of all, it is necessary to select the busbar pipe of appropriate specifications according to the busbar cross-section circumference. It is usually required that the circumference after shrinkage is slightly smaller than the busbar circumference to ensure a tight fit. When cutting pipe, use a sharp knife to cut vertically to avoid burrs or beveled edges. Before inserting, the surface of the busbar should be cleaned to remove oil, dust and sharp burrs to prevent local stress concentration or puncture of the insulation layer due to the presence of foreign matter after heating and shrinkage. It is recommended to use an industrial hot air gun with a reflector as a heating tool. The temperature is set between 120°C and 140°C.

 

The heating tool is moved in a spiral shape from the middle of the busbar pipe to both ends to avoid local overheating or scorching caused by long-term fixed-point heating. For longer busbars, the heating shrinkage can be completed in multiple times, with an overlap of about 50 mm each time to ensure continuous coverage of the joints. After heating is completed, allow the busbar to cool naturally. Do not use cold air or water cooling to accelerate the cooling to avoid internal stress. For batch construction scenarios of Heat Shrink Tubing BusBar, tunnel-type heat shrink furnaces can be used to achieve continuous automated operations. The temperature control accuracy and heating uniformity are better than those of hand-held heat guns.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

If your project is facing insulation challenges in a small space, or you need to find customized Heat Shrinkable Busbar Insulating Tape solutions in special environments, please contact our engineering team today and let us provide you with professional selection advice and sample support.