Insulated Copper Busbar

What Is an Insulated Copper Busbar?

An insulated copper busbar is a high-conductivity copper conductor that is fully encapsulated with a solid insulation layer such as epoxy resin, silicone rubber, or heat-shrink material. This design allows for safe, compact, and efficient power distribution in low-, medium-, and high-voltage systems. Compared with bare busbars, insulated designs reduce clearance requirements, improve safety, and minimize maintenance.

For applications requiring vibration resistance or space flexibility, we also provide insulated flexible busbar solutions and insulated flexible copper bars, which combine the electrical advantages of copper with mechanical flexibility.

How It Is Made

1. Copper Conductor Preparation – High-conductivity ETP Copper is cut, punched, and bent according to the design.

2. Surface Treatment – Tin plating, nickel plating, or silver plating is applied for anti-oxidation and improved conductivity.

3. Insulation Coating – Epoxy powder coating, extrusion of halogen-free insulation, or heat-shrink tubing encapsulates the busbar.

4. Curing & Quality Control – Insulation is heat-cured and tested for dielectric strength, creepage distance, and thermal resistance.

Key Features & Advantages

• Superior Electrical Performance – Copper conductor offers low resistance and high current capacity.

• Compact & Space-Saving – Insulation allows reduced phase spacing, ideal for compact switchgear or battery packs.

• Enhanced Safety – Full insulation prevents accidental contact and arc flash risk.

• Vibration Resistance – Insulated flexible busbar and insulated flexible copper bars absorb vibration and thermal expansion stress.

• Low Maintenance – Dustproof and moisture-resistant insulation reduces cleaning requirements.

• Customization Options – Length, thickness, hole patterns, and insulation color can be customized to your needs.

Material Selection

Technical Specifications

Application Areas

• Low- and medium-voltage switchgear and power distribution panels

• Battery energy storage systems and busbar for battery bank

• EV battery packs and power electronics

• Renewable energy inverter connections (solar/wind)

• Data center UPS and power distribution units

Installation & Maintenance Notes

• Ensure proper tightening torque for all bolted joints.

• Maintain correct creepage and clearance distances as per system voltage.

• Avoid sharp bending that could damage insulation.

• Periodically inspect for discoloration, cracking, or loose connections.

Why Choose Us?

• Direct Copper Busbar Manufacturer – Full control over quality and lead time.

• Customization Expertise – We design and produce insulated copper busbar, insulated flexible busbar, and insulated flexible copper bars to your exact specifications.

• Certified Quality – Products tested to IEC, UL, and RoHS standards.

• Global Supply Capability – Fast delivery and technical support worldwide.

FAQ

Q1: What current rating can your insulated copper busbar handle?
A1: From 400A up to 6000A continuous, with short-circuit withstand up to 100kA.

Q2: Can I get flexible designs?
A2: Yes, we offer insulated flexible busbar and insulated flexible copper bars for dynamic or vibration-prone applications.

Q3: Do you support custom hole punching and plating?
A3: Absolutely, we can provide custom hole patterns, tin/nickel/silver plating, and insulation color options.