Performance analysis of dense 6101 aluminium flat busbar

The shell of the intensive 6101 aluminium flat busbar is mainly made of steel, aluminum alloy, and aluminum magnesium alloy. The steel shell is made of magnetic material, which is prone to eddy current heating when powered on, affecting heat dissipation and increasing losses, resulting in poor energy efficiency. The aluminum alloy shell is made of non-magnetic material, which can avoid eddy current loss, has better thermal conductivity than steel, and has better energy-saving effect.

Aluminum magnesium alloy has higher mechanical strength on the basis of no eddy current and high thermal conductivity, and is currently the most comprehensive performance shell material. The shell assembly process of 6061 aluminum busbar mainly includes bolt assembly, manual riveting, and automated riveting. Bolt connections are prone to loosening due to long-term vibration, posing a risk of short circuits; Manual riveting has higher reliability and good electrical continuity, but poor quality consistency and low efficiency; Automated riveting can achieve standardized production, stable assembly quality, and higher production efficiency.

The conductor of the intensive 6101 aluminium flat busbar is mainly made of electrical hard aluminum bars. According to relevant standards, the aluminum content should not be less than 99.50%, and the purity directly affects the conductivity. The common surface treatment processes include copper-clad aluminum, tin plating, and copper plated tin plated double coating. The copper-clad aluminum process is prone to residual air between copper and aluminum, causing electrochemical reactions, and the difference in expansion coefficients between the two materials is large, resulting in poor connection stability.

Tin plating on aluminum can improve oxidation problems, but tin has a higher resistivity and is affected by the skin effect, resulting in a decrease in the current carrying capacity of the Aluminum busbar electrical power connector. The dual plating process of copper plating first and then tin plating has high requirements and costs, but the copper layer can improve the conductivity, the tin layer can enhance the anti-corrosion effect, the metal bonding is stable, there is no expansion coefficient matching problem, and the comprehensive performance is the best.

The commonly used insulation materials for Customized aluminium busbars include PVC heat shrink tubing, polyester film, and powder coated insulation. PVC heat shrink tubing has a large thickness, poor thermal conductivity, and is prone to aging. Its service life generally does not exceed 15 years. Polyester film has high insulation strength, can be stretched to ultra-thin thickness, is conducive to heat dissipation, has excellent heat resistance and durability, and is suitable for long-term stable operation scenarios. Powder coated insulation requires a certain thickness to meet the withstand voltage requirements. Overly thick coatings can hinder the heat dissipation of Aluminum flexible connections, and are prone to detachment and wear during assembly and operation vibration, posing a short circuit hazard and relatively low reliability.

The core advantages of dense Flexible aluminium connections are compact structure, fast heat dissipation, and low losses. Traditional sockets use simple bending treatment, which can form a local air layer, resulting in a high temperature rise at the socket position, and the internal air is prone to condensation, accelerating interface corrosion.

At present, the more reliable method is the aluminum bar extension process, which directly forms the terminal structure through mechanical extrusion to avoid high resistance problems caused by welding. It can maintain a dense structure throughout the 6101 aluminum bus bar, with no gaps between conductors. The system has low impedance, good heat dissipation, low temperature rise, and impact resistance, while saving installation space and greatly improving power supply safety and stability.

We can provide high-quality 6101 aluminium flat busbars and professional surface treatments such as silver plating, perfectly adapting to the high conductivity and high reliability requirements of dense busbars. Welcome to call or write to inquire about customization. We will provide you with suitable product solutions and professional technical support.