Must see for engineering research and development: 4 process technologies for Flexible copper busbars insulation layer

The shrink insulation sleeve process is a common way of insulation treatment for Flexible copper busbars. The core process is to directly wrap the copper foil soft connection surface with PVC sleeve, and then heat and shrink it into shape in a high-temperature furnace. The advantage of this process lies in its low cost, easy operation, strong adaptability, and suitability for bending simple straight Multilayer copper foils flexible busbars; Its limitations are also quite obvious. For copper foil soft connections with irregular structures, complete wrapping cannot be achieved, so it is only suitable for scenarios with simple structures. The insulation layer colors are mainly orange and black.

In response to the issue of Flexible copper busbars with irregular structures not being able to use insulation sleeves, the immersion molding process has become the preferred solution. This process melts PVC material into a liquid state at high temperature, immerses the copper foil soft connection in the molten material for a certain period of time, and then takes it out. After the material cools down, a complete PVC insulation layer can be formed on the surface of the copper foil. Its characteristics are fast processing speed, smooth insulation layer surface, bright color, and excellent insulation performance. It is a commonly used insulation treatment method for irregular Copper flexible busbars in the field of new energy vehicles.

Extrusion processing technology is an emerging insulation layer processing technology in recent years, which uses specialized extrusion equipment to directly extrude and wrap insulation materials on the surface of Multilayer bus bars. This process is suitable for Automotive copper busbars used in large power equipment, with the advantages of high processing efficiency and fast speed, making it suitable for large-scale production of large-sized products. Common insulation materials include PVC, PA12, etc. The processing principle is similar to the traditional manufacturing method of copper wires and cables, which can achieve continuous molding of the insulation layer and ensure insulation uniformity.

For products such as Flexible copper laminated busbars with special insulation requirements (such as insulation layer shape and material limitations), the above three processes cannot meet the requirements and injection molding processes need to be used. This process requires the development of injection molds that are suitable for the appearance of the product, and then the insulation material is injection molded in one go through injection molding equipment to fully wrap the copper foil soft connection. The injection molding process can be adapted to a wide range of insulation materials, including PVC, TPE, TPU, and other injectable materials. However, its limitations lie in its high cost and the need for mold development costs, making it suitable for scenarios with special customization needs.

If you have any questions about the selection and customization requirements of Flexible copper busbars insulation technology, please feel free to contact us for consultation at any time. We will provide professional technical answers and adaptation solutions to help you efficiently promote research and development and production work.