Busbar surface insulation treatment effectively prevents short circuits from accidental contact, reduces oxidation and corrosion, and ensures long-term stability in conductivity and heat dissipation. In the power industry, insulation layers enhance safety in high-voltage environments, improve corrosion resistance, and extend the lifespan of electrical equipment, ensuring reliable operation and operator safety. This meets the stringent demands of modern electrical systems for both efficiency and safety.

In new energy busbar manufacturing, common insulation solutions include powder coating (EP epoxy resin), PVC coating, and heat shrink tubing (EVA and PE). Each offers unique advantages suited to specific applications.

1. Powder Coating Insulation Process

Process Characteristics:

In the powder coating process, power busbars are heated and immersed in epoxy resin (EP) powder, which melts and adheres to form a dense insulation layer. This layer, typically 0.5mm thick, provides strong electrical insulation, corrosion resistance, and excellent heat dissipation. With high temperature and voltage resistance, it is ideal for special-shaped rigid busbars, enhancing product reliability and durability.

Advantages:

• Superior Insulation Performance: Epoxy resin powder provides high electrical insulation, effectively preventing short circuits and leakage.

• Strong Corrosion Resistance: The coating resists chemical corrosion, making it suitable for custom busbars exposed to harsh environments.

• High Mechanical Strength: The coating is hard and wear-resistant, capable of withstanding mechanical impact and abrasion.

• Excellent Heat Dissipation: The EP insulation layer offers enhanced heat dissipation, particularly suited for irregularly shaped busbars.

Application Scenarios:

• High-Voltage Environments: Given the excellent electrical insulation properties of powder coating, it is suitable for high-voltage equipment in power systems, such as distribution cabinets, transformers, and EV battery systems, ensuring safe operation.

• Harsh Environments: With strong corrosion and weather resistance, powder coating is ideal for use in industrial environments that are humid or highly corrosive.

• Complex-Shaped Busbars: The powder coating process provides a uniform insulation layer for complex or irregularly shaped busbars, making it suitable for power busbars in new energy battery systems.

2. PVC Insulation Process

Process Characteristics:

The PVC insulation process involves heating PVC to a liquid state and immersing the busbar to form a smooth, uniform insulating layer with strong adhesion. PVC insulation provides excellent resistance to corrosion, acids, alkalis, and is flame retardant. The thickness, color, and voltage resistance can be customized, with eco-friendly materials available in various colors. This simple process is ideal for mass production.

Advantages:

• Cost-Effective: PVC coating is a relatively simple process with lower equipment and material costs, making it ideal for large-scale production and cost-conscious projects.

• Adjustable Insulation Thickness: By controlling immersion time and temperature, the thickness of the insulation layer can be adjusted to meet different voltage requirements.

• Good Weather Resistance: PVC material exhibits excellent weather resistance and aging properties, performing well in environments with varying temperatures and humidity.

Application Scenarios:

• Standard Electrical Environments: PVC-coated busbars are commonly used in indoor power distribution systems, particularly in medium and low-voltage environments.

• Low-Cost Projects: For projects with strict cost controls, the PVC coating process is a highly economical solution, often used in small to medium-sized power engineering or new energy equipment busbar insulation.

3. Heat Shrink Tubing Insulation Process

Process Characteristics:

Heat shrink tubing made of EVA or PE is applied to the electrical busbar by heating, causing it to shrink and form a tight, uniform insulation layer. This provides excellent insulation, high-temperature resistance, and enhances mechanical strength and shock resistance. EVA suits low-voltage environments, while PE, with greater strength and hardness, is ideal for higher pressure or mechanical stress. The process is simple and widely applicable.

Advantages:

• Simple Operation: Heat shrink tubing is easy to apply and flexible in its use, requiring minimal equipment, making it suitable for on-site applications or small-scale busbar insulation treatment.

• Excellent Heat and Wear Resistance: EVA and PE materials exhibit good heat resistance and wear resistance, maintaining stable insulation performance even at high temperatures.

• Convenient Repairs: If the insulation layer of the heat shrink tubing is damaged, it can be replaced locally, reducing downtime and increasing operational flexibility.

Application Scenarios:

• Special-Shaped Busbars: For battery busbars where powder coating or PVC coating is not feasible, such as flexible busbar joints, heat shrink tubing is an ideal solution due to its flexibility.

• On-Site Installation and Repairs: Heat shrink tubing is suitable for applications that require on-site installation or post-installation repairs, especially when the equipment has already been installed or the wiring is complex, offering a fast and reliable insulation solution.