Products

Home page

filter

Water cooled

The radiator

Insulated soft copper bar

Soft connection

Braided wire

Motor housing

Insulated flexible copper bar

keywords：

insulated copper soft

classification：

Product display

hotline：

+86-29-83888032

Online message

Insulated flexible copper bar

The insulated soft copper bar,also known as laminated insulated soft copper bar and flexible busbar,is made of multi-layer corona proof flat thin copper sheet conductors superimposed,and the outer layer is extruded to cover the insulation layer.
1、Structural composition
1.Conductor
The conductor of insulated soft copper bar adopts T2 soft copper strip,which can be divided into bare copper and tinned copper.Copper strip specifications are 15.5×0.8，20×1，24×1，32×1，40×1，50×1，63×1，80×1，100×1.The number of laminations is 2 to 12.
2.Insulating layer
At present,the insulating layer of insulated soft copper bar has two materials:special polyvinyl chloride(PVC)and thermoplastic elastomer(TPE).TPE has the characteristics of low smoke and halogen-free.
2、Production standard
There is no special standard for insulated flexible copper bar in the world.The United States borrows UL758 electronic wire standard for production certification,and Xi'an Longyuan first began to manufacture it with reference to gb/t5023 insulated cable standard and UL758 electronic wire standard.
3、Product characteristics of insulated soft copper bar:
1.Easy to process and shape
Because the copper conductor can slide freely in the insulating layer,the insulating soft copper bar has infinite bending and torsion characteristics.The wide thickness ratio of copper strip varies greatly,which makes the flexible copper bar easy to bend in the thickness direction,but has high rigidity in the width direction,so that the insulated flexible copper bar can bend out any spatial configuration by hand or with simple tools,which is convenient for installation and wiring.
2.High current carrying capacity
Due to the skin effect,when passing through AC,the current inside the conductor is actually very small,and the current is concentrated in a thin layer near the outer surface of the conductor.The multilayer flat conductor structure of insulated soft copper bar makes the same conductor cross-sectional area can carry more passing current.Thus,the amount of conductor material is reduced,which not only reduces the weight,but also saves the layout space.
The following is a comparison of the required sections of insulated flexible copper bars and ordinary round cables under three current carrying capacities:
Current carrying capacity insulated soft copper bar sectional area circular cable sectional area
250A 40mm2 95mm2
630A 160mm2 300mm2
1000A 300mm2 555mm2
3.Convenient installation
After the insulating soft copper bar is bent and punched,the spatial shape of the structure can not only avoid the interference area,but also easily return to the original shape after bending during installation.The contact surface can be directly connected with the terminal and slightly fixed,eliminating the complex connection and fixation of traditional cables and busbar.
4、Application of insulated soft copper bar
Due to the excellent characteristics of insulated soft copper bar,it has become the first choice for electrical wiring.It will gradually replace the application of cable in electrical wiring,and the hard busbar of non main structure will also be gradually replaced by soft copper bar.
Technical parameters of soft copper bar conductor:
Annealed electrolytic copper:Cu%≥99.9%
Conductivity:≥56.2s/m
Vickers hardness:＜50hv
Tensile strength:≥200MPa
Elongation:≥30%
Technical parameters of soft copper bar insulation layer:
PVC:PVC
Color:Black/orange
Coating method:extrusion molding
Dielectric strength:＞23kv/mm
Oxygen index level:30%
Elongation after 135℃/7-day aging test:＞180%
Tensile strength:＞20MPa
Operating temperature:-30℃to+105℃
Flame retardant:self extinguishing
Working voltage range:750V(10531 line type)1000V(11343 line type)
Compressive strength:(15min/50hz):
To ground＞15kV
Busbar room＞30KV
Conductor type:bare copper strip/tinned copper strip
Standard length:2m or 3M
Standard product specification and allowable current:

Conductor size and pieces (mmmmpieces)	Section (mm²)	Current-load(A)			Conductor size and pieces (mmmmpieces)	Section (mm²)	(A)Current-load
Conductor size and pieces (mmmmpieces)	Section (mm²)	△T=20K(3)	△T=40K(4)	△T=50K(5)	Conductor size and pieces (mmmmpieces)	Section (mm²)	△T=20K(3)	△T=40K(4)	△T=50K(5)
15.50.82	24.8	125	175	200	4012	80	240	330	380
15.50.83	37.2	160	210	240	4013	120	330	480	540
15.50.84	49.6	195	265	295	4014	160	400	560	630
15.50.86	74.4	225	320	360	4015	200	450	630	710
15.50.88	99.2	265	380	430	4016	240	480	680	750
15.50.810	124	300	420	480	4018	320	600	830	920
2012	40	170	240	270	40110	400	670	920	1030
2013	60	230	320	360	5013	150	400	570	650
2014	80	270	380	440	5014	200	490	700	790
2015	100	300	430	490	5015	250	540	780	880
2016	120	330	470	530	5016	300	590	840	950
2018	160	400	560	620	5018	400	680	1000	1130
20110	200	420	580	650	50110	500	750	1100	1300
2412	48	200	280	320	6315	315	650	900	1000
2413	72	250	360	410	6316	378	690	980	1100
2414	96	280	410	460	6318	504	840	1200	1350
2415	120	330	470	530	63110	630	920	1300	1450
2416	144	360	510	570	8015	400	700	1100	1230
2418	192	420	590	670	8016	480	780	1210	1360
24110	240	500	700	790	8018	640	950	1400	1570
3212	64	230	320	360	80110	800	1090	1550	1730
3213	96	280	410	460	10015	500	860	1250	1400
3214	128	320	460	520	10016	600	950	1380	1530
3215	160	390	550	610	10018	800	1100	1580	1760
3216	192	440	620	700	100110	1000	1220	1710	1920
3218	256	510	720	822	100112	1200	1300	1800	2010
32110	320	600	840	930

Model selection guidance:
The current carrying capacity of insulated flexible copper bar is related to the section size and temperature of flexible copper bar,as shown in the table above.The following factors should be considered in model selection:
① Current carrying capacity
② Allowable busbar temperature rise
③ Busbar width
The calculation formula of busbar temperature rise(△T)is as follows:
△T=Ta-Tc
TC:ambient temperature.
TA:the temperature of the soft copper bar after power on(important note:for general electrical equipment,Ta should be≤105℃).
Model selection examples(for reference only):
Requirements:the ambient temperature of the equipment is 40℃,the carrying capacity of the flexible copper bar is 510a,the maximum temperature on the flexible copper bar is not more than 100℃,and the width of the flexible copper bar is not more than 40mm.
Model selection:according to the formula,the maximum allowable temperature rise can be calculated as 60℃(100℃-40℃=60℃),so the specification can be selected as 32×one×4 flexible copper bar:the temperature rise of this specification of flexible copper bar under the load current of 520A is 50a,so this type selection is feasible and has sufficient safety margin.

Introduction of insulated flexible busbars
UL758 certified(E336413)
CE certified
SGS certified:RoHS compliant
UL94 V-0
Operating temperature:-30℃to+105℃.
Operating voltage:600Vac/750Vdc;1000Vac/1500Vdc
Types available:max.width 120mm,max.thickness 12mm
Over 50 clients all over the world,especially in America
Two production lines
Strengths of insulated flexible Cu busbars compared with flexibles
A：Lead time：less processing procedure,shorter lead time,more suitable for mass production
B：Appearance properties:the insulated flexible Cu busbars do not need the process of high-temperature molecular welding,this can be avoided internal oxidation;Finished flexibles need electroplating,this may cause acid corrosion.
C：Flame resistance：the insulation flame retardant grade is UL94-V0,this is the highest flame resistance grade.But,welding flexible is setting heat-shrink tube on external,and the flame resistance grade of heat-shrink tube is VW-1.So,the insulated flexible Cu busbars are better than flexibles.
D：Cost analysis：to compared with flexibles,the process of flexibles is complex,and the cost of surface treatment is higher,while,due to the strict environmental requirements,all plating are centralized management in electroplating industrial district,so the distance is longer,and the cost of transportation is higher.However,for the flexible insulated bus bars,we only purchase the electroplated copper strip,and we what the process we only need to do is processing(bending),so the process is less,the delivery is faster,and the cost is lower.There exist some rejection rate for the flexibles,but Insulated flexible busbars can basically achieve 100%pass rate.

Radiator

Water cooling plate