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Insulated Flexible Busbars for Panel Boards
Flexible busbars feature multi-layer laminated copper strips with a tightly integrated PVC extruded insulation layer. The compact, uniform insulation is free of bulges and pinholes, providing high dielectric strength and reliable electrical isolation. The flexible, space-saving design enables efficient installation in high-current and high-voltage power distribution systems.
Insulated Flexible Busbars for High-Current Power Distribution
Flexible busbars are made from high-conductivity copper or aluminum and feature a continuous extruded PVC insulation layer. The extrusion process forms a uniform, durable coating with strong abrasion resistance, providing reliable electrical insulation and stable performance. Their flexible, space-saving design simplifies installation and improves assembly efficiency, making them suitable for high-current power distribution in energy storage systems, switchboards, and panel boards.
Specifications
Conductor Material: T2 Copper, ≥99.95% Cu
Surface Finish: Bare Copper, Tin Plated, or Nickel Plated
Current Rating: 125–2,000 A
Dimensions: Customizable by the number of copper layers, layer width, and thickness to match the terminal
dimensions of connected equipment.
| Parameter | Copper Conductivity | Insulating Material | Dielectric Strength | Operating Temperature | Operating Voltage | Flame Retardant Rating | Environmental Protection |
| Values | ≥57MS/m | PVC | 20KV/mm | -40℃~105℃ | DC 1500V | UL94 V-0 | RoHS |
Insulated Flexible Busbar Details
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Conductor Material: |
Cu Strip or Al Strip T2 Copper Aluminium (1060 ) Other materials customizable. |
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Surface Treatment: |
Bare, Tin Plating, Nickel Plating |
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Application: |
EV Battery Pack Connections, Energy Storage Systems, Electric Cabinets, Panel Boards |
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Quote Response Time: |
After receiving the drawings and verifying their feasibility, it will take 5-7 days to make a quotation. |
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Quality Management Standard: |
Meet Auto Industry IATF16949 |
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Eco-friendly Certificate: |
RoHS |
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Delivery Time: |
The delivery time will take about 15-20 days after payment. |
Why Choose Insulated Flexible Busbars?
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Continuous Extrusion Forming: High-efficiency one-pass molding reduces labor and supports large-scale production.
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Small Bending Radius: Maintains insulation integrity during tight bends, suitable for dense system designs.
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Environment-Compliant PVC: Meets environmental standards and offers reliable heat resistance and aging performance.
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High Insulation Reliability: Provides strong electrical protection for high-voltage operation.
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Durable Mechanical Strength: Wear-resistant, shock-resistant, and ideal for battery module and PDU interconnections.
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One-Step Production: Conductor feeding and insulation extrusion completed simultaneously, improving consistency and lowering manufacturing cost.
Where Can Insulated Flexible Busbars Be Used?
Flexible busbars provide flexible, compact connections for high-current power distribution. Multi-layer copper conductors with continuous PVC extrusion offer reliable insulation and easy routing in space-constrained systems.
- Energy Storage: Battery Cabinets, PCS, DC Combiner, Energy Storage Systems
- Power Distribution: Switchboards, Switchgear, Distribution Panels
- Solar & Renewable Energy: PV Inverters, Energy Storage Inverters, DC Systems
- Industrial Power: Power Supplies, Converters, Motor Control Cabinets
