Insulated Flexible Busbar

A standard flexible busbar exposes the copper conductor along its full length — safe in open air with adequate clearance, but requiring careful routing in congested panels. An insulated flexible busbar adds a continuous polymer sleeve over the flexible body, so the conductor can run close to grounded surfaces, adjacent phase bars, or structural metalwork without risk of flashover or accidental contact. The terminals are left bare for bolted connection. All the flexibility and conductivity of the copper core is retained; the insulation simply removes the clearance constraint.

PVC is cost-effective and suitable for indoor switchgear operating below 70°C — the most common choice for low-voltage panels and distribution boards. TPE offers better cold-temperature flexibility, improved oil and chemical resistance, and a wider temperature range than standard PVC, making it preferred for industrial and automotive environments. Silicone handles continuous operating temperatures up to 180°C or higher, remains flexible after prolonged heat exposure, and is specified for traction equipment, high-temperature motor connections, and applications where PVC or TPE would harden or crack over time.

Yes. Insulation can be applied over braided copper busbars for high-flex, vibration-absorbing applications, or over laminated copper busbars for high-current static joints where phase-to-phase or phase-to-earth isolation is required. The core type is selected first based on the mechanical requirement — braided for movement and vibration, laminated for current density and flat contact surfaces — and the insulation is then specified based on voltage, temperature, and environment.

Insulation wall thickness and material grade are selected to meet the required working voltage. Standard configurations cover low-voltage applications up to 1kV. Medium-voltage insulation for higher voltage classes is available on request, with wall thickness, dielectric strength, and material grade specified according to the applicable standard. Please state the system voltage and relevant standard when enquiring.

Insulated flexible busbars are used in low-voltage switchgear and motor control centres where phase bars run close together, EV battery pack interconnections where insulation is mandatory, traction equipment and rail vehicles operating in confined spaces, UPS and energy storage systems requiring both flexibility and phase isolation, and transformer secondary connections where the flexible link must clear adjacent metalwork without additional sleeving.

Please specify: core type (braided or laminated), Length (L) × Width (W) × Thickness (T), cross-sectional area, terminal shape and hole diameter, insulation material (PVC / TPE / Silicone), operating voltage, and continuous operating temperature. For complex routing shapes or non-standard terminal configurations, a drawing or sample is welcome. Both prototype and volume production are supported.