How to Prevent Leakage with Heat Shrink Tubing Busbar

According to the Ministry of Emergency Management, 32% of low-voltage electrical accidents in China in H1 2025 were caused by busbar leakage. A heat shrink tubing busbar uses heat-shrinkable insulation to block current leakage, but improper use reduces its effect. This article explores core steps to prevent leakage, performance tests, scenario optimization, application fields, and Xiamen APOLLO's solutions.

 

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1. Clean Busbar Surface Thoroughly​

Before installing, wipe the busbar with alcohol to remove oil, rust, and dust. Residues will cause gaps between the busbar and insulation, leading to moisture penetration and leakage. This step is critical for heat shrink tube polyolefin busbar.​

 

2. Select Matching Insulation Specifications​

Choose busbar insulating tubing with suitable shrink ratio (usually 2:1 or 3:1) and thickness (0.8-1.2mm). A too-thin tube breaks easily; a too-thick one can't fit tight. It ensures no gaps for leakage.​

 

3. Control Heating Temperature and Speed​

Heat the tube evenly with a hot air gun (temperature 120-150℃). Move the gun at 5-10cm/s to avoid local overheating. Overheating causes tube cracking, while underheating leaves it loose-both lead to leakage.

 

 

1. Insulation resistance test: Use a 500V megohmmeter to measure the resistance of busbar insulation sheet. It should be ≥10¹⁰ Ω. A lower value means the insulation has defects and may leak.​

 

2. Voltage withstand test: Apply 1.5x the rated voltage (e.g., 6kV for 0.4kV systems) to PVC insulation busbar for 1 minute. No breakdown or leakage current (≤1mA) means it meets safety requirements.​

 

3. Sealing test: Immerse the installed heat shrink tube polyolefin busbar in water for 24 hours. Measure insulation resistance again-no significant drop (≤10%) means it blocks moisture and prevents leakage.

 

 

1. Humid Environments (e.g., Coastal Areas)​

Add silicone sealant at the ends of busbar insulating tubing. It fills tiny gaps between the tube and busbar, preventing salt mist and moisture from seeping in. This extends leakage-free service life by 3-5 years.​

 

2. High-Temperature Environments (e.g., EV Charging Piles)​

Choose heat shrink tube polyolefin busbar with high-temperature resistance (up to 125℃). Common tubes soften at 80℃, leading to cracks and leakage. High-temperature models maintain insulation integrity.​

 

3. Vibration Environments (e.g., Industrial Pumps)​

Paste a busbar insulation sheet between the busbar and bracket. It reduces friction from vibration, avoiding tube wear and leakage. The sheet should have a hardness of Shore A 60-70 for best buffering.

 

 

Heat shrink tubing busbar plays a key role in leakage prevention across fields. In new energy EV charging piles, it blocks rainwater leakage, ensuring safe charging. In residential low-voltage distribution boxes, PVC insulation busbar prevents accidental contact leakage, protecting families. In food processing workshops (high humidity + oil), busbar insulating tubing resists oil and moisture, avoiding production-stopping leakage accidents. These scenarios prove its reliability.

 

 

Xiamen APOLLO's heat shrink tubing busbar uses high-purity polyolefin material (purity ≥99.9%) with insulation resistance ≥10¹¹ Ω-10x higher than industry average. It has a uniform thickness (1.0±0.1mm) and shrink ratio 3:1, fitting tightly to busbars. It passes insulation resistance, voltage withstand, and sealing tests, meeting IS09001-2015, IATF16949, and UL standards.​

 

We offer flexible custom services: adjust the length (100-5000mm), thickness (0.6-1.5mm), and color of busbar insulating tubing for different scenarios (coastal, high-temperature, vibration). We have global sea, land, and air logistics-deliver to Asia in 3-5 days, Europe in 7-15 days. Our after-sales team provides 24-hour technical support, including on-site installation guidance and leakage troubleshooting, ensuring zero leakage risks for customers.