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About A&J
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
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Products&Service
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
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Solutions
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
Epoxy coated busbar
An epoxy coated busbar is a high-performance electrical conductor, typically made of copper or aluminum, that is encapsulated in a uniform, seamless layer of epoxy resin. This coating transforms it from a simple metal strip into a fully insulated, protected component. It provides excellent dielectric strength to prevent short circuits, along with superior resistance to moisture, dust, chemicals, and mechanical damage. Ideal for harsh and demanding environments, these busbars are essential in high-voltage switchgear, energy storage systems (ESS), rail transportation, and industrial automation, ensuring safe, reliable, and maintenance-free power distribution in critical applications.
Product Details
Epoxy Coated Busbar Explained: Product Overview & Key Benefits
At A&J LINK, we provide robust and reliable Epoxy Coated Busbar solutions for high-voltage, high-protection, and complex application environments. This advanced power connection component involves applying a uniform, dense epoxy resin coating onto precisely machined copper or aluminum busbars to form an insulating protective layer. Our products are specifically designed to meet stringent environmental challenges, delivering excellent electrical performance alongside superior mechanical and environmental protection.
Epoxy Coated Busbar: Core Features & Key Advantages
Our Epoxy Coated Busbars stand out in demanding applications due to their exceptional design and performance.
Excellent Insulation & Comprehensive Protection
- High Dielectric Strength: Utilizes high-quality epoxy resin materials to form a uniform, pore-free insulating layer, providing insulation withstand voltage ratings up to several kilovolts (e.g., 10kV+), effectively preventing creepage and electrical short circuits.
- Superior Environmental Resistance: The coating offers excellent defense against moisture, dust, salt spray, chemical corrosion, and UV exposure, making it ideal for humid, dusty, polluted, or outdoor environments.
- Robust Mechanical Durability: The tough epoxy coating protects conductors from mechanical impact, vibration, abrasion, and contaminants, significantly extending product service life.
- Enhanced Safety: Coating materials typically comply with flame retardant standards such as UL 94V-0, improving system fire safety. The insulated surface also reduces the risk of accidental electric shock during installation and maintenance.
Flexible & Reliable Custom Design Capabilities
- Adapts to Complex Geometries: The spraying process is ideal for single or multiple independent busbars with complex shapes, irregular structures, or numerous connection points, enabling complete three-dimensional insulation coverage.
- Integrated Assembly Design: Connection terminals, bolts, and other components can be pre-assembled before coating, achieving a seamless integration of insulation and structure for greater reliability.
- Thermal Management Options: Epoxy resin formulas with thermal conductive fillers can be selected to address specific heat dissipation needs while maintaining excellent insulation.
- Stable & Reliable Performance: The seamless, monolithic insulating layer avoids potential interface issues found in multi-layer insulation methods, ensuring long-term electrical and mechanical stability.
Epoxy Coated Busbar Technical Specifications & Standards
| Parameter | Specification / Capability |
|---|---|
| Conductor Material | High-purity copper, aluminum alloy |
| Insulation Coating | High-performance epoxy resin system |
| Rated Voltage | Up to several kilovolts (e.g., 10kV or higher, customizable) |
| Rated Current | Customized based on conductor cross-section and cooling conditions |
| Operating Temperature Range | -40°C ~ 130°C (depending on resin system) |
| Temperature Class | Commonly Class H (180°C) or above |
| Protection Rating (IP) | Can achieve IP67 or higher (combined with structural design) |
| Flame Retardant Rating | UL 94V-0 |
| CTI Value | ≥ 400V (Comparative Tracking Index) |
| Coating Thickness | Customizable, typically 0.2mm - 1.0mm |
Epoxy Coated Busbar Applications: Where Are They Used?
Our Epoxy Coated Busbars are widely used in scenarios demanding extremely high insulation, protection, and reliability, including:
- High-Voltage Electrical Equipment: Internal connections for switchgear, distribution cabinets, transformers, and instrument transformers.
- New Energy & Energy Storage (ESS): Internal high-voltage connections for energy storage battery packs, DC side of photovoltaic inverters, and charging pile power modules.
- Rail Transportation & Marine: Traction and auxiliary power supply systems for locomotives, subways, and ships.
- Industrial Automation: Power connections for large motor drives, frequency converters, UPS systems, and equipment in harsh environments (e.g., mining, chemical industries).
- Specialized & Military Equipment: Applications requiring superior protection against moisture, mold, salt spray, and corrosive elements.
Why Choose A&J LINK for Your Epoxy Coated Busbars?
We go beyond standard products by offering expert Co-design and Manufacturing Services tailored to your precise needs:
- Process Expertise: Precise control over coating thickness and uniformity ensures consistent, high-performance insulation across every product.
- Materials Science Knowledge: We recommend the optimal epoxy resin system based on your specific application environment (temperature, chemical exposure, mechanical stress).
- Full-Process Quality Control: Strict checks at every stage—from conductor pre-treatment (cleaning, roughening), coating, and curing to final inspection—guarantee unparalleled reliability.
- Comprehensive Testing & Validation: We provide detailed validation reports, including high-voltage testing, insulation resistance, damp heat cycling, and adhesion testing, ensuring compliance with industry standards.
Get Your Customized Epoxy Coated Busbar Solution
No matter how complex your environmental and electrical challenges are, A&J LINK's Epoxy Coated Busbars can provide a robust and reliable insulated connection solution. Contact our technical team today to discuss your specific requirements and receive a tailored proposal.
Contact Us for a Custom Solution (Email)
FAQ
What coating characteristics should be considered when selecting an epoxy-coated bus bar?
- Insulation Rating: The dielectric strength (kV/mm) of the coating and the final product's withstand voltage.
- Thermal Properties: The coating's thermal conductivity, long-term operating temperature (UL Temperature Index), and flame retardant rating (e.g., UL94 V-0).
- Mechanical Properties: The coating's adhesion, flexibility, abrasion resistance, and impact resistance.
- Environmental Suitability: Whether it meets specific requirements like mildew resistance or chemical resistance.
What are the typical application scenarios for epoxy-coated bus bars?
- Internal connections in high-voltage power cabinets and switchgear.
- New Energy Sector: Connections within battery packs for Energy Storage Systems (ESS), charging pile modules.
- DC busbars in rail transit and marine power systems.
- Any application requiring insulation of bare copper busbars in harsh, dusty, or humid environments.
What are the advantages of the epoxy coating insulation layer?
- Excellent Insulation: Forms a uniform, seamless insulating layer with high dielectric strength, preventing creepage.
- Superior Protection: Waterproof, moisture-proof, salt spray resistant, chemically resistant, and provides good mechanical protection.
- Heat Dissipation: Some thermally conductive epoxy formulas help transfer and dissipate heat from the conductor.
- Design Flexibility: Allows for coating of single bus bars with extremely complex shapes, achieving complete coverage insulation.
What is the fundamental difference between epoxy-coated bus bars and laminated bus bars?
- Structure: Epoxy-coated bus bars are typically single or multiple independent copper bars coated with a uniform layer of epoxy resin insulation via a spraying process. Laminated bus bars are an integrated structure of multiple conductor and insulation film layers pressed together.
- Performance: Epoxy-coated bus bars focus more on high insulation strength, environmental corrosion resistance, and mechanical protection, suitable for medium/high voltage applications with stringent insulation requirements. Their electrical performance optimization (e.g., for low inductance) is generally not as refined as that of laminated bus bars.
- Cost & Application: For ultra-high voltage (e.g., several kV and above) or for single conductors with very complex shapes requiring full-coverage insulation, epoxy coating is often a more cost-effective choice.
How do we request samples or proceed with small-batch trial production?
- You can submit a request via the "Contact Us" page on our website or directly contact your sales engineer. Please provide confirmed drawings and technical specifications. We will provide a sample quote, prototyping timeline, and a clear test plan. We support small-batch trial production orders to assist with your system-level validation.
Can you design bus bars to fit our complete system structure or PCB layout?
- Absolutely. This is a core advantage of our service. We specialize in co-design. You simply need to provide PCB files (e.g., ODB++, Gerber), 3D models or dimension drawings of key components (e.g., IGBT modules, capacitors), and enclosure spatial constraints. Our engineers will design a bus bar that integrates perfectly with your system, offers optimal routing, and ensures easy installation and the most reliable electrical connections.
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