How Heat Shrink Tube Insulated Busbars Achieve Insulation

 

 

(I) Core Insulation Material: "Three in One" of Temperature Resistance, Corrosion Resistance and Insulation Performance

 

• Excellent electrical insulation performance: The volume resistivity of the material is as high as 10¹⁴ - 10¹⁶Ω・cm, and the breakdown field strength can reach 20 - 30kV/mm, which is far higher than that of traditional insulation materials (for example, the breakdown field strength of epoxy resin board is about 15kV/mm). It can effectively prevent current leakage and avoid short - circuit accidents caused by insulation failure.

 

• Wide temperature range adaptability: The working temperature range of cross - linked polyolefin material covers from - 40℃ to 125℃ (some high - temperature resistant models can reach 150℃). It can not only withstand the high - temperature environment when power equipment operates in summer, but also adapt to the low - temperature working conditions in cold areas. It avoids insulation layer cracking and aging caused by temperature changes, and ensures long - term insulation stability.

 

• Strong corrosion resistance and mechanical strength: The surface of the insulation layer is smooth and dense, which can effectively resist the erosion of corrosive substances such as humidity, dust and acid - base gas in the air. At the same time, it has good tensile and impact resistance (tensile strength ≥12MPa, elongation at break ≥200%). It can protect the busbar from external damage such as mechanical collision and vibration, and prolong the service life of the product.

 

 

(II) Structural Design: "Tight Fit + Multi - layer Protection" to Eliminate Insulation Blind Spots

 

• Tight fit heat shrink process: During the production process, the size of the heat shrink tube is customized according to the specifications (width, thickness, shape) of the busbar. After heating, it can shrink tightly and fit on the surface of the busbar, forming an insulation layer with "no bubbles and no wrinkles". This tight fit structure can prevent air and moisture from entering the gap between the insulation layer and the busbar, and avoid partial discharge caused by air ionization in the gap, which may lead to insulation breakdown.

 

• Optional multi - layer composite insulation protection: For high - voltage (such as 10kV and above) or harsh environment scenarios, some Heat Shrink Tube Polyolefin Busbars will adopt a multi - layer structure of "basic heat shrink insulation layer + flame retardant layer + wear - resistant layer". Among them, the flame retardant layer (added with magnesium hydroxide, aluminum hydroxide and other flame retardants) can prevent the spread of flame in fire accidents, meeting the UL94 V - 0 flame retardant standard; the wear - resistant layer (such as modified polyolefin material) can improve the wear resistance of the insulation layer surface, which is suitable for scenarios where the busbar needs frequent maintenance or the installation space is narrow.

 

 

 

(I) Physical Barrier: Building a "Current Barrier" to Prevent Leakage Current

 

• Blocking surface leakage current: The insulation layer covers the entire surface of the busbar (including the side, edge and connection part), forming a continuous insulation barrier. It avoids the formation of a conductive path on the busbar surface due to the attachment of dust and moisture, thus preventing the generation of surface leakage current. At the same time, the high surface resistance (≥10¹³Ω) of the insulation layer further reduces the flow capacity of the surface current, ensuring that the surface leakage current can be controlled below the μA level even in a humid environment.
• Blocking volume leakage current: The high volume resistivity (10¹⁴ - 10¹⁶Ω・cm) of the cross - linked polyolefin material makes it an excellent "current insulator". Even under the action of high voltage, the leakage current through the inside of the insulation layer volume is very small (usually ≤10⁻⁹A), which is far lower than the safety limit of the power system. It fundamentally avoids the insulation heating and aging problems caused by excessive volume leakage current.

(II) Electric Field Optimization: Improving the Electric Field Distribution on the Busbar Surface to Reduce the Risk of Partial Discharge

 

• Smooth insulation layer surface: After the heat shrink tube is closely attached to the busbar, it can convert the "sharp structure" at the edge and corner of the busbar into a smooth arc transition, reducing the electric field concentration points. According to the electric field simulation data, after using the heat shrink tube for insulation, the electric field strength at the busbar edge can be reduced from 50 - 80kV/cm of the bare busbar to 20 - 30kV/cm, which is lower than the breakdown field strength of air, effectively inhibiting the generation of partial discharge.
• Control of insulation layer dielectric loss: The cross - linked polyolefin material used in the heat shrink tube has a very low dielectric loss factor (tanδ) (≤0.005 at 50Hz frequency). It can reduce the electric field energy loss caused by dielectric loss, avoid local heating of the insulation layer, and further reduce the insulation aging speed. At the same time, the low dielectric loss characteristic can also reduce the electric field distortion, ensure the uniform distribution of the electric field, and improve the overall insulation reliability.

 

 

 

• New energy photovoltaic power stations: The busbars in the photovoltaic inverter operate in a high - temperature environment (up to more than 80℃) and high humidity. Traditional bare busbars are prone to insulation failure due to corona discharge. After using heat shrink tube insulated busbars, they can effectively resist the high - temperature and high - humidity environment. The operation data of a large - scale photovoltaic power station shows that the insulation failure rate of the inverter using Busbar Insulation Sheet has decreased from 0.8 times per unit per year to less than 0.1 times per unit per year, and the operation stability has been significantly improved.

 

• Subway traction system: The busbars in the subway traction converter bear high voltage (DC 1500V), large current (up to 2000A) and are greatly affected by train vibration. The tight fit structure and high mechanical strength of the heat shrink tube insulated busbar can effectively resist the insulation layer falling off caused by vibration. At the same time, its excellent insulation performance can avoid the shutdown accident of the traction system caused by the insulation failure of the busbar. After the application in a subway line, the failure rate of the traction system has decreased by 30%.

 

• Intelligent distribution rooms: The equipment in the intelligent distribution room is dense, the busbar installation space is narrow, and phase - to - phase short circuits are prone to occur. The insulation layer of the heat shrink tube insulated busbar can effectively isolate the busbars of different phases and prevent phase - to - phase discharge. At the same time, its compact structural design can save more than 50% of the installation space, adapting to the development trend of "miniaturization and integration" of intelligent distribution rooms.

 

We offer a complete range of Heat Shrink Tube Insulated Busbars with custom solutions for various industries. Our products feature high conductivity, excellent insulation, and strong environmental adaptability. We use high-quality materials and strict testing to ensure stable performance and long service life.Our team provides quick response technical support and reliable after-sales service. We offer competitive prices and flexible delivery options to meet your project needs. Whether for power systems, new energy, rail transit, or industrial control, our busbars deliver efficient, safe, and durable connections.We have partnered with many international customers.These clients trust our products for high quality, stable performance, and timely delivery. Looking forward to cooperating with you!