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Flexible Copper Busbar
1. What Is A Bus Bar Electrical?Bus Bar Electrical is a conductive component used in power systems to collect, distribute, and transmit electrical energy efficiently. It replaces traditional cables with high-conductivity materials (copper/aluminum), reducing resistance losses and simplifying wiring.
Key Types:
By Material: Solid copper, tin-plated aluminum, flexible copper/aluminum.
By Form: Rigid straight bars, flexible laminated strips, multi-layer composites.
Precision manufacturing ensures conductivity, durability, and safety:
Material Selection:
Copper: Ultra-high conductivity (58 MS/m) for high-power applications.
Aluminum: Lightweight (1/3 density of copper), cost-effective, with tin-plating for corrosion resistance.
Forming Processes:
Rigid Bars: Extruded or rolled for precise cross-sectional dimensions.
Flexible Bars: Laminated or braided for bendability.
Surface Treatments:
Tin-Plating: Prevents oxidation, reduces contact resistance, and enhances solderability.
Insulating Coatings: Epoxy or polyester for outdoor/high-humidity environments.
Quality Assurance:
Conductivity testing (resistivity ≤0.0172 Ω·mm²/m for copper).
Salt spray tests (72h NSS for tin-plated aluminum).
Tailored solutions for diverse industries:
| Application Field | Typical Use Cases | Recommended Busbar Type |
|---|---|---|
| Renewable Energy | PV inverters, wind converters, battery energy storage systems (BESS) | Tin-plated aluminum (rigid/flexible) |
| Electric Vehicles | Battery packs, charging piles, motor controllers | Flexible copper (vibration-resistant) |
| Industrial Power | Factory switchgear, data centers, substations | Solid copper (high-conductivity, durable) |
| Rail Transit | Metro power systems, high-speed train traction converters | Tin-plated aluminum (lightweight, corrosion-resistant) |
| Aerospace | Aircraft power distribution, satellite power modules | Flexible aluminum (ultra-light, reliable) |
Core advantages for mission-critical systems:
Ultra-Efficient Conductivity: Copper at 58 MS/m; tin-plated aluminum achieves ~80% of copper’s conductivity.
Lightweight Design: Aluminum reduces weight by 67% vs. copper, cutting installation costs.
Corrosion Resistance: 5–15μm tin-plating withstands salt spray, humidity, and industrial pollutants.
Flexible Configuration: Minimum bending radius of 5x thickness for tight spaces.
Customization: Tailored cross-sections (e.g., 10×50mm), lengths, and hole patterns.
Key considerations for optimized performance:
Current-Carrying Capacity:
Calculate minimum cross-sectional area using:
(K: Temperature correction factor; J: Current density; ΔT: Allowable temperature rise)
2. Thermal Management:
Add fins or vents to limit temperature rise to ≤50°C (typical for solid copper).
3. Connection Optimization:
Bolted: Torque specs (e.g., 12–15 Nm for M8 bolts).
Welded: Tin-plating ensures void-free joints.
Safety Compliance:
Meets UL 857, IEC 61439 standards; dielectric strength ≥1,000V.
Five reasons to partner with us:
Global Certifications:
Compliant with UL, RoHS, CE, ASTM B230, GB/T 5585 standards.
Material & Process Excellence:
99.9% pure electrolytic copper and 6063 aluminum; uniform tin-plating (±1μm tolerance).
Customization Mastery:
Supports irregular shapes, multi-layer composites, and embedded temperature sensors.
Full-Lifecycle Support:
From design simulation and prototyping to mass production.
Market-Proven Reliability:
Solutions validated in 200+ MW renewable plants, 500,000+ EVs, and 1,000+ industrial systems.
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