GRL flexible insulated copper busbar 5mm fabrication good quality

Overview of flexible insulated copper busbar

What is a flexible insulated copper busbar?

A flexible insulated copper busbar is a type of electrical conductor, distinct from its traditional rigid counterparts, made from high conductivity copper.

Its design incorporates a series of thin copper laminates in a flat, flexible arrangement, allowing for much greater flexibility and adaptability in installation and use.

This innovative structure enables the busbar to bend, twist, and flex, accommodating a wide range of configurations and applications while maintaining excellent electrical conductivity and efficiency.

Technical Parameter of flexible insulated copper busbar

Material: T2 copper foil, copper content >99.95% Single piece thickness: 0.03mm

0.05mm

0.10mm(regular)

0.20mm

0.30mm

0.40mm

0.50mm

Surface treatment: bare copper, tin plating, nickel plating, silver plating Cross-sectional area: 1.5mm2-5000mm When placing an order, please specify the following values:

Length (L)x Width (W)x Thickness (T)

Product shape and hole type

Aperture(d)

Single piece thickness (conventional 0.10mm)

 

Structure and application

The flexible insulated copper busbar is made of multiple layers of highly flexible flat thin copper sheets, and the outer layer is made of extrusion-wrapped heating ground layer. The insulation layer currently includes special polyurethane (PVC) and thermoplastic elastomer (TPE). Two materials.

TPE has low smoke and halogen-free properties. The insulation is black. Since the copper conductor can slide freely within the insulation layer, the non-threaded soft busbar has eyeless bending and torsion characteristics.

At the same time, the multi-layer flat conductor structure of the explosion-proof flexible insulated copper busbar enables the same conductor cross-sectional area to carry a larger passing current, thus reducing the amount of conductor material, which not only reduces the weight, but also saves space.

Features of flexible insulated copper busbar

The core appeal of flexible copper busbars is their unique blend of flexibility and performance.

Unlike rigid busbars, which require precise alignment and can be cumbersome to install in complex configurations, flexible copper busbars are easy to handle and install in tight spaces.

This adaptability does not come at the expense of electrical performance; similar to rigid busbars, flexible copper busbars provide superior current carrying capabilities and efficient power distribution.

Not only that, the flexible copper busbar has good wear resistance and resistance to substances such as oil, solvents and chemicals: PVC insulation material can withstand high temperatures up to 80 degrees Celsius.

Advantages of flexible insulated copper busbar

1、Enhanced Design Flexibility: The ability to bend and flex allows for creative and efficient use of space within electrical systems. Designers can work around obstacles and optimize layouts, reducing the need for custom connectors and complicated wiring schemes.

2、Simplified Installation and Maintenance: The inherent flexibility significantly simplifies the installation process, making it faster and less labor-intensive. Maintenance and upgrades are also more straightforward, as the flexible busbar can be easily adjusted or reconfigured.

 

3、Improved Reliability and Safety: By reducing the number of electrical connections and eliminating the need for additional joining components, flexible copper busbars enhance the reliability of the electrical system.

This streamlined design minimizes potential failure points and improves overall safety.

4、Superior Electrical Performance: Despite their flexible nature, these busbars maintain excellent electrical conductivity and efficiency.

They efficiently handle high currents, reducing energy losses and improving the overall performance of the power distribution system.

5、Vibration Resistance: In environments where machinery or equipment may cause vibrations, flexible copper busbars demonstrate superior performance by absorbing and withstanding these forces, ensuring a stable and uninterrupted power supply.