Aluminum Busbar with Insulation Cover

Our Aluminum Busbars with insulation cover are engineered for safe, lightweight, and efficient power distribution across a variety of applications, including electrical cabinets, energy storage systems (ESS), electric vehicles, solar inverters, and industrial switchgear. Compared to copper, aluminum provides an excellent conductivity-to-weight ratio and significant cost advantages, making it an ideal solution for modern power systems.

Key Features of Aluminum Busbars with Insulation

1. Lightweight and Cost-Efficient
Aluminum offers up to 50% weight reduction compared to copper while maintaining high electrical conductivity. This reduces overall system weight and cost without compromising performance, making Aluminum Busbars perfect for EVs and portable energy systems.

2. Durable Insulation Layer
Each busbar is laminated or coated with high-performance insulation materials such as PVC, epoxy powder coating, PET film, or heat-shrink tubing. The insulation ensures safe operation up to 1500V DC, preventing short circuits and improving system reliability.

3. Customizable Shapes and Sizes
We offer full OEM/ODM support for aluminum busbars, including custom bending, punching, plating (tin or nickel), multi-layer stacking, and 3D structure busbars to meet unique system designs and installation requirements.

4. Excellent Thermal Performance
Aluminum naturally dissipates heat, maintaining stable operation in harsh environments. Our insulated aluminum busbars can operate reliably between -40°C and +125°C, making them suitable for high-current and temperature-sensitive applications.

5. Corrosion Resistance
Optional anodizing, tin plating, or epoxy coating ensures long-term resistance to corrosion, even in outdoor or industrial environments. This guarantees reliable performance in energy storage systems, solar installations, and EV power modules.

Product Specifications

Applications

• Energy Storage Systems (ESS): Safe and efficient DC distribution for batteries and storage racks.

• Electrical Cabinets & Panels: High-current distribution in industrial or commercial electrical panels.

• DC Distribution Systems: Reliable power flow for low-voltage and high-current applications.

• Solar Inverters & Charging Stations: Lightweight, corrosion-resistant busbars for renewable energy systems.

• Electric Vehicle Power Modules: Reduced weight and high conductivity for EV battery interconnects.

• Power Conversion & Control Systems: Stable busbar performance in PLC cabinets, control panels, and automation equipment.

Advantages of Our Aluminum Busbars

• Up to 50% weight reduction compared to copper

• High conductivity with cost-effective material selection

• Robust insulation ensures safety at voltages up to 1500V DC

• Customizable shapes, layers, and finishes to meet OEM requirements

• Excellent thermal dissipation and long-term corrosion resistance

• Supports plating options (tin, nickel) for enhanced surface conductivity

FAQ – Aluminum Busbar with Insulation

Q1: What insulation materials are available for aluminum busbars?
A1: We provide PVC, polyolefin heat-shrink tubing, epoxy powder coating, and PET film insulation, based on voltage, temperature, and environmental requirements.

Q2: Can aluminum busbars be plated for better conductivity?
A2: Yes. We offer tin-plating or nickel-plating to enhance surface conductivity and provide additional corrosion resistance.

Q3: Are aluminum busbars suitable for outdoor use?
A3: Yes. With anodized or coated finishes, our aluminum busbars are corrosion-resistant and ideal for outdoor or industrial environments.

Q4: Can you produce curved or multi-layer busbars?
A4: Absolutely. We support CNC bending, multi-layer lamination, and 3D busbar structures customized to your system specifications.