Insulated tooj liab Busbar

 

Raws li tus thawj coj tshiab hauv insulating busbar technology, peb lub tuam txhab tau cog lus rau kev tshawb fawb kev txhim kho, thiab kev tsim cov high-kawg insulating busbars, integrating laminated busbar qauv tsim nrog ntau- txheej txheej rwb thaiv tsev txheej txheem, thiab ingeniously tsim plaub cov khoom matrices:Hmoov Coated Busbars, PVC Dipping Insulated Busbars, PET Insulated Busbar rau EV Film Capacitors, thiab Laminated Busbars. Nrog rau cov khoom siv engineering innovation thiab cov txheej txheem thev naus laus zis tshiab, peb cov khoom lag luam tau txais kev pabcuam tshiab lub zog tsheb hluav taws xob tsav tsheb, cov khoom siv hluav taws xob sib xyaw ua ke, cov khoom siv hluav taws xob thauj mus los, thiab cov khoom siv hluav taws xob muaj hluav taws xob, tsis tu ncua muab lub teeb yuag, qis -inductance, thiab siab - kev ntseeg tau hluav taws xob kev sib txuas rwb thaiv tsev daws teeb meem rau cov neeg siv khoom thoob ntiaj teb.

 

 

 

 

1. Laminated Busbar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.1 Khoom siv thiab txheej txheem zoo
Tus neeg xyuas pib:siab -purity oxygen- dawb tooj liab (C11000, tooj liab purity Ntau dua lossis sib npaug li 99.99%), conductivity Ntau dua los yog sib npaug rau 58 MS / m, tooj liab busbar nto roughness Tsawg dua los yog sib npaug rau 0.8μm, txo cov tawv nqaij poob.
Rwb thaiv tsev txheej: txais ob - txheej lossis ntau- txheej txheej txheej txheej (puab txheej polyimide PI zaj duab xis + txheej txheej hloov kho epoxy resin PET zaj duab xis), nrog rau qib voltage ntawm 3kV / mm, ib nrab tso tawm<5pC (IEC 60270 standard), ensuring signal stability in high-frequency scenarios.
Tus qauv tsim: txhawb nqa ntau- txheej txheej, interlayer qhov sib txawv qhov tseeb ± 0.05mm, parasitic inductance txo rau<10nH/cm (1/5 of traditional busbar), adapting to SiC MOSFET high-frequency switching requirements.

 

Laminated busbar vs. ib leeg- txheej tooj liab busbar: Hauv - sib piv qhov tob ntawm kev ua kom sov dissipation

 

Hom	Siab- zaus poob (10kHz)	Daim tawv nqaij cuam tshuam	Qhov ntsuas qhov tseeb (300A tam sim no)
Laminated busbar	Txo los ntawm 42%	Multi- txheej tooj liab ntawv (tsawg dua lossis sib npaug li 0.3mm) tshem tawm cov nyhuv ntawm daim tawv nqaij	Lub zog cia converter: kub nce 38℃(ambient 25 degree)
Tib - txheej tooj liab busbar	Base tus nqi 100%	Khoom tooj liab busbar (Ntau dua lossis sib npaug li 2 hli) Poob concentrated ntawm qhov chaw	Tib yam kev ua haujlwm: kub nce 55℃(ambient 25 degree)
Lub hauv paus ntsiab lus: Cov ntawv ci tooj liab nyias (0.1-}0.5mm) ntawm Laminated Copper BusBar ua rau tam sim no sib npaug sib npaug, zam qhov kub dhau ntawm ib txheej tooj liab busbar vim cov nyhuv ntawm daim tawv nqaij (qhov tob ntawm daim tawv nqaij ≈8.5mm @ 50Hz, tsuas yog 0.66mm ntawm 10kHz).

 

1.2 Cov txheej txheem ntau lawm
Copper phaj laser txiav (qhov tseeb ± 0.1mm) → Ua ntej- txheej txheej rwb thaiv tsev (nqus ib puag ncig tiv thaiv- npuas) → Kub nias sib xyaw (180℃/ 5MPa siab sib sau) → Peb- kev sib koom tes tshawb pom (qhov yuam kev<0.2mm) → Electrical performance test (withstand voltage, insulation resistance, temperature rise).

 

1.3 Daim ntawv thov scenarios thiab tus nqi ntawm cov neeg siv khoom
 

Daim ntawv thov scenario	Kev daws teeb meem zoo	Cov laj thawj tseem ceeb
High frequency and high power (>10kHz)	Laminated busbar	Tsawg poob + kub sib npaug tsim kom tsis txhob IGBT thermal tsis ua haujlwm
Loj tam sim no thiab tsawg zaus (<50Hz)	Tib - txheej tooj liab busbar + milling qhov	Tus nqi qis, txaus ib zaug - taw tes cua kub dissipation (xws li ib txwm UPS)
Qhov chaw txwv + kev vibration ib puag ncig	Laminated busbar	Peb -dimensional heat dissipation + anti- qaug zog (xws li lub zog tshiab)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Powder Coated Busbar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.1 Khoom siv thiab txheej txheem zoo
Conductor optimization:T2Y2 toojhmoov txau, tiv thaiv kev tiv thaiv Tsawg dua los yog sib npaug li 0.1mΩ, tam sim no nqa lub peev xwm nce 15% piv nrog liab qab tooj liab (80℃kub nce).
Coating technology: electrostatic spraying epoxy powder (UL 94 V-0 certification), thickness 0.2-0.5mm controllable, adhesion up to level 1 (GB/T 9286 cross-cutting method), salt spray resistance >1000 teev (ASTM B117), haum rau thaj chaw ntug dej hiav txwv / tshuaj lom neeg.
Tus nqi kom zoo dua: Piv nrog rau cov txheej txheem dipping, cov khoom siv tau nce los ntawm 30%, thiab tag nrho cov nqi raug txo los ntawm 18-25%.

 

Cov txheej txheem tseem ceeb (piv nrog kev txhaj tshuaj molding / pleev xim)

 

Txuas	Hmoov txau txheej txheem zoo	Cov ntaub ntawv ntsuas
Ua ntej-kev kho mob	Tshuaj etching + sandblasting (roughness Ra 3.2-6.3μm)	Txheej adhesion> 5N / cm (ASTM D3359)
Kev xaiv hmoov	Epoxy resin (150-200μm) lossis polytetrafluoroethylene (80-120μm)	Kub tiv taus 220℃(epoxy resin) vs txhaj molding 180 degree
Kev tswj xyuas	180℃× 20min (fluidized txaj electrostatic txau)	Thickness uniformity ± 15μm (kev lag luam tus qauv ± 25μm)
Core tawg	Tsis muaj kuab tshuaj volatilization (VOC<50mg/m³), no dripping on the edge (minimum fillet R0.3mm)	Qhov deb ntawm qhov creepage yog 28% luv dua li ntawm dip -painted busbar (IEC 60664-1 ntawv pov thawj)

 

2.2 Cov txheej txheem ntau lawm
Copper busbar laser txiav → CNC stamping / dabtsi yog khoov (Nyiv AMADA CNC khoom) → Surface sandblasting (Sa2.5 qib kev huv) → Electrostatic spraying (Robot cia li tswj cov zaj duab xis thickness) → High - kub curing (200℃/ 30 feeb) → Cua nruj (IP67 tus qauv).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.3 Daim ntawv thov scenarios thiab tus nqi ntawm cov neeg siv khoom

 

Daim ntawv thov scenario	Tus nqi tseem ceeb ntawm hmoov- tshuaj tsuag busbar	Mob cov ntsiab lus ntawm lwm txoj kev daws teeb meem
800V + lub zog tshiab tsheb	Ultra{0}}thin rwb thaiv tsev (0.1-0.2mm) + du npoo (anti-corona)	Ib txheej txheej tuab (Ntau dua lossis sib npaug ntawm 0.5mm) siv qhov chaw
Kev lag luam thiab kev lag luam zog cia (2000V)	CTI 600 tiv thaiv- creeping, txhawb nqa qhov ntom ntom	Cov txheej impregnation yog ib qho yooj yim kom nqus noo noo, ua rau txo cov rwb thaiv tsev
Rail Transit (kev vibration + roj paug)	Kev cuam tshuam - tiv thaiv txheej + tiv thaiv - roj nkag	Tsob ntoo insulating xim yog ib qho yooj yim kom poob tawm
Photovoltaic inverter (sab nraum zoov)	UV-cov hmoov resistant (ntxiv TiO₂), 10-xyoo yellowing Performance index<5	Ordinary txheej bowdlerization hauv 3 xyoos

 

3. PVC Dipping Insulated Busbars

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.1 Khoom siv thiab txheej txheem zoo
Kev kho substrate: Tshuaj passivation ntawm tooj liab busbar (chromate txheej txheem),tsis muaj corrosion nyob rau hauv ntsev tsuag kuaj > 720h, ua kom muaj kev ntseeg siab nyob rau hauv ib puag ncig tropical/marine.
Plastic txheej kev ua tau zoo:
PVC hom: qis-cov nqi daws teeb meem, nplaim hluav taws kub qib UL 94 V-2, haum rau cov hluav taws xob qis qis (AC 1000V lossis tsawg dua).
Nylon 12 hom: resistant rau diesel / lubricating roj corrosion, cuam tshuam lub zog> 50kJ / m² (ISO 179 tus qauv), resistant rau -40℃low-temperature cuam tshuam.
 

3.2 Cov txheej txheem ntau lawm
Copper busbar laser txiav → CNC stamping / dabtsi yog khoov (Nyiv AMADA CNC khoom) → tooj liab busbar pickling thiab ua kom → preheating rau 220℃(txhim kho lub zog ntawm cov yas txheej) → impregnation nrog plasticizing kua (lub sij hawm / kub tsis siv neeg tswj) → dej txias thiab shaping → 1 laser trimming (AC voltage) 3kV / 60s tsis tawg).

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.3 Daim ntawv thov scenarios thiab tus nqi ntawm cov neeg siv khoom
 

Ncaj nraim mus rau qhov mob taw tes ntawm kev yuav khoom: "Terminator" ntawm rwb thaiv tsev tsis ua haujlwm
Piv nrog rau qhov tsis xws luag ntawm cov kev daws teeb meem ib txwm muaj (kub shrink tube / laminated rwb thaiv tsev)

 

Scenario	Kub shrink tube busbar teeb meem	Dip yas busbar daws	Cov ntaub ntawv txhawb nqa
Roj teeb pob vibration (5-500Hz)	Thaum tshav kub kub shrink tube tawg (ua tsis tiav tom qab 30,000 cycles)	Dip yas txheej (Shore hardness 85A) tsim kua muag zog 45MPa	100,000 cycles tsis muaj kab nrib pleb
Ntug dej ntsev tsuag ib puag ncig (500h)	Rwb thaiv tsev txheej blistering, tooj liab busbar corrosion	Dip yas txheej (thickness 0.8-1.2mm) ntsev tsuag tshuaj ntsuam 1000h yam tsis muaj xeb liab	BYD Dolphin roj teeb pob pov thawj
Fast charging kub nce (120℃ncov)	Rwb thaiv tsev cov ntaub ntawv softening (PVC kub deformation kub 70 degree)	Dip yas khoom (PBT + iav fiber) kub tsis kam -40℃~ 150 degree	Cov pawg supercharging ua haujlwm tsis tu ncua rau 1000 teev yam tsis muaj qhov txawv txav

 

4. EV PET Insulated Busbar rau EV Film Capacitor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4.1 Khoom thiab txheej txheem zoo

Tus neeg tsav tsheb innovation:ultra-thin tooj liab strip (0.8mm thickness)+ soldering lossis tiv thaiv brazing txheej txheem, ua tiav ib ntu ntawm 100mm² thiab tam sim no ntawm 300A, thiab 20% sib zog dua aluminium busbar.
Insulation kev puas tsuaj:
Biaxially oriented PET zaj duab xis: CTI Ntau dua lossis sib npaug rau 600V (50% nce piv rau PI zaj duab xis), corona kuj lub neej ＞ 800h (IEC 61934 tus qauv).
Cov qauv sib xyaw: PET + iav fiber ntau txheej txheej, tsim kua muag lub zog ＞ 80N / mm (DIN 53363 tus qauv), zam kev pheej hmoo ntawm cov roj teeb pob.
Automotive certification: dhau AEC-Q200 kev ntsuam xyuas kev ntseeg siab, txhawb ISO 26262 kev nyab xeeb qib ASIL-C.

 

4.2 Cov txheej txheem ntau lawm

Qauv los yog me me batch xaj: laser txiav → CNC stamping / dabtsi yog khoov → PET zaj duab xis ua ntej -lamination → kub pressing compound (kub / siab kaw- voj tswj) → tuag- txiav cov duab → online AOI nrhiav tau (kev paub tsis raug 0.02mm²) → dynamic tam sim no nqa cov kev ua haujlwm (simulating tam sim no).

 

Loj - ntim xaj: nruam stamping ntawm tooj liab strip progressive tuag → PET zaj duab xis ua ntej -lamination → kub pressing compound (kub/siab kaw-loop tswj) → tuag- txiav puab → online AOI nrhiav kom tau (tsis xws luag paub tseeb 0.02mm²) → dynamic tam sim no nqa tej yam kev mob (simulating kev ua hauj lwm).

 

4.3 Daim ntawv thov scenarios thiab tus nqi ntawm cov neeg siv khoom
Roj teeb module kev twb kev txuas: voltage sampling busbar impedance Tsawg tshaj los yog sib npaug zos rau 0.5mΩ, kub txawv <2℃(800A nruam fais fab), txhim kho BMS raug.
Cov neeg tau txais txiaj ntsig: Tom qab lub tsheb tshiab - ua kom muaj zog tau txais nws, lub zog ceev ntawm lub pob roj teeb tau nce 7%, thiab dhau lub teb chaws tus qauv thermal runaway diffusion test.

 

 

 

 

Dimension	Laminated busbar	Hmoov tshuaj tsuag rwb thaiv tsev	Dip-coated rwb thaiv tsev	PET rwb thaiv tsev rau EV
Nqi	High (precision lamination txheej txheem)	Nruab nrab (batch automation)	Medium (mould amortization)	High (automotive qib khoom)
Kev tiv thaiv ib puag ncig	Zoo heev (nqus ntim)	Zoo (IP67 tiv thaiv)	Zoo heev (tag nrho kaw)	Zoo heev (chemical corrosion kuj)
Siv tau voltage	3kV (siab zaus rwb thaiv tsev)	1kV (lub zog zaus scenario)	1.5kV (qhov nruab nrab voltage)	1.5kV (DC system)
Kev xa khoom ceev	7-15 hnub (Customization)	3-7 hnub (tus qauv khoom)	5-10 hnub (pwm adaptation)	10-20 hnub (kev kuaj xyuas qib tsheb)

 

 

 

 

 

1. Hardware zog
Kev txawj ntse rhiav: tag nrho cheeb tsam ntawm 8,000 square meters, nruab nrog tag nrho tsis siv neeg busbar ntau lawm kab (progressive tuag nruam xuas nrig ntaus tshuab + laser txiav + CNC xuas nrig ntaus / dabtsi yog khoov), qhov kub thiab av noo tsis tu ncua - thaj tsam dawb (raws li ISO 14644-1 Chav Kawm 8 tus qauv).
Pwm chaw: 20 CNC cov cuab yeej ua haujlwm (qhov tseeb ± 0.005mm), txhawb nqa 48-teev nrawm pwm qhib, nrog nws cov pwm tsim thiab tsim thiab ua haujlwm.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Kev cog lus zoo
Cov cuab yeej kuaj:
- High Voltage Tester (AC 10kV / DC 15kV withstand voltage)
- Industrial CT (3D duab ntawm qhov tsis xws luag)
- Programmable Constant Temperature and Humidity Chamber (-70℃~ 300℃limit test)
Certification System:
- Automotive Kev Lag Luam:TIAB SA 16949, PPAP Qib 3
- International Standards: UL 467, CE, RoHS

 

 

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