Epoxy powder coating has great advantages when it comes to insulating busbars. It has many benefits over traditional sleeving and wrapping of busbars, especially when complex shapes are required.

Traditionally, busbars have been wrapped in fibreglass tape or sleeved in heatshrink to insulate them them; both processes are time consuming and unsuitable for convoluted shapes.

With the move to pure electric drivetrains in cars and aircraft, there is an ever-increasing demand to fit more busbars into a confined space, creating the need for more complex shaped busbars than ever – this is where epoxy powder coated insulation comes in to its own.

Epoxy powder coating is an electro-static process so, regardless of the complexity of the shape, the powder is attracted to all the exposed metal areas (contact areas are simply masked off prior to coating). If required, the busbar can be nickel, tin, silver or gold plated prior to coating so that the contact areas have maximum conductivity and environmental protection.

Electropak Ltd offer both copper and aluminium busbars for where lightness is required for flight and can coat the Busbars using HLG03R or the fluidised bed variant HGC20R.

We also have the facilities to test the dielectric strength of the insulation. All busbars are checked for pin hole using a Holiday meter and also insulation tested for dielectric strength at 5000 v D.C. Dielectric strength is typically 1.4 Terra ohms with a 0.3 mm thick insulation coating.

Contact us today to see how we can cater to your busbar requirements.