Solid Copper Bus Bar Industry Technology Review

As the core conductive material in power transmission and transformation systems and electrical equipment, copper busbars are widely used in motor windings, high and low voltage electrical appliances, switch contacts, and power supply and distribution installation wires. A high-quality Copper BusBar must have high electrical conductivity, good thermal conductivity, excellent corrosion resistance and electroplating properties, while meeting the dual requirements of mechanical strength and forming processing performance. With the technological upgrading of the power industry, the market has set higher standards for the surface quality and performance consistency of copper busbars.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The surface quality of copper busbars is mainly determined by three aspects: smoothness, flatness and defect control, and is directly affected by the properties of raw materials, production processes and environmental conditions. In Bus Bar Design, it is important to consider the effects of temperature and humidity on surface oxidation and corrosion. Copper begins to oxidize slowly at room temperature. When the temperature rises to 100 degrees Celsius, black copper oxide is generated. The oxidation rate increases in a parabolic curve above 400 degrees Celsius. In a humid environment, water vapor will accelerate the corrosion of the bus bar copper surface, and the growth rate of the oxide film will significantly accelerate as the humidity increases. In addition, if the remaining lubricants, residual acids and other substances during the stretching process are not handled properly, they will cause surface discoloration or corrosion marks, which will affect the adhesion of subsequent coatings.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The traditional "flattening-drawing-annealing" process has obvious limitations: the surface of the product is prone to defects such as burrs, peeling, and pitting, which increases the risk of insulation breakdown of the transformer winding; the resistivity and mechanical properties are uneven, making it difficult to meet the impedance matching requirements; it is difficult to produce copper busbars with a width-thickness ratio greater than 10 or a large cross-sectional area; lubricant residues on the surface of bare wires affect the quality of the paint film; the process is complex, high energy consumption, long cycle and serious environmental pollution.

The modern continuous extrusion process represents the technological development direction of Busbar Fabrication. This process uses hot extrusion plastic molding to effectively eliminate surface defects of raw materials, avoid warping and burrs common in traditional processes, and ensure the smooth surface of the Ground Bus Bar. Under the conditions of high temperature and high pressure and three-dimensional compressive stress, casting defects such as pores and shrinkage porosity inside the copper rod are compacted, and the defects will not expand due to axial tensile stress like the drawing process. The copper busbar produced by this process has fine grain size, dense structure, and eliminates the annealing process. It not only reduces energy consumption, but also avoids product performance fluctuations caused by uneven furnace temperatures, ensures uniform performance along the length direction, and meets the strict impedance matching requirements of transformers, motors and other equipment.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In order to further improve product quality, manufacturing companies need to take a number of improvement measures. First of all, it is necessary to ensure that the charge is dry and the melt coverage is strengthened to prevent oxide inclusions and the occurrence of "hydrogen disease". Secondly, the copper busbar blank needs to go through a pickling process after heating and extrusion to remove copper oxide on the surface. In terms of mold selection, hot extrusion dies usually use cermet molds that have both ceramic and metallic properties, while drawing dies mostly use carbide materials, and the inner holes need to be brightly polished. The selection of process lubricants also needs to be optimized. Water-based emulsions are widely used because they have the lubricity of oil and the cooling properties of water. Finally, during the stretching, straightening and shearing processes, surface protection must be done to prevent the bright copper busbar surface from being scratched during handling or processing, ensuring that the final delivered product has a perfect finish and flatness.

 

 

Our company specializes in the R&D and manufacturing of high-performance copper busbars. We provide one-stop services from Solid Copper Bus Bar Design to Busbar Fabrication to meet the needs of complex working conditions such as high voltage and high current. If you need to purchase copper bus bar for sale or customize battery bus bar, please contact us for detailed plans.