Tuling Flexible Busbar
Tuling manufactures flexible busbar connectors of customized dimensions. Our bus bars are made of conductive metals (e.g., copper and aluminum) and can handle current from 125 A to 2800 A.
You can avail of both insulated and non-insulated flexible bus bars from us. Our heat shrinkage insulating sleeves make the busbar flexible by reducing the contact surface. We offer low smoke and flame-retardant insulators to ensure safety.
Our flexible bus bars can be bent, folded, and twisted without damaging their integrity. Moreover, for ease of installation, we have removed the lugs from our flexible bus bars. This makes the connections simpler and eliminates faulty connection risks.
All our products are developed according to ISO 9001:2015, UL, RoHS, and REACH standards.
Tuling Flexible Busbar Products
Laminated bus bars are used for high-current applications.
Advantages of Tuling Flexible Busbar
Laminated or braided busbars have flexibility for easy folding, bending, and twisting.
Tuling flexible bus bars takes up 25% less space and fits on any narrow installation area.
High-conductive flexible bus bars increase power transmission efficiency.
Our flexible busbars withstand extreme vibration, shock, and thermal expansions.
Tuling Flexible Busbar Technical Specification
| Conductor Materials | Copper (58.0 × 10^6 S/m),
Aluminum (37.7 × 10^6 S/m) |
| Surface Finishing | Tin, silver, nickel |
| Insulation Material | Heat shrinkage PVC or TPE |
| Insulation thickness | Down to 0.07’’ |
| Dielectric strength | 20 kV/mm |
| UL/CSA/IEC operating voltage | 1000V, 1500V |
| EN 50264-3 operating voltage | 16000V |
| Working Temperature | -50°C to 135°C |
| Flammability Rating | UL® 94V-0 |
Tuling Flexible Busbar Dimension and Ampacity
At Tuling, we can manufacture flexible busbars of any kind, e.g., single-layer, multi-layer, wire-type, and folded. Typical dimensions of flexible bus bars are up to 1200 mm². Tuling can optimize bus bars of larger dimensions on demand.
We can also customize the number of layers you want in the bars. Our technology allows us to use conductive metal foils with a minimum of 0.05 mm thickness.
With the dimensions, we can control the ampacity of our bus bars up to 2800A. Please visit our flexible copper busbar current carrying capacity chart for a better understanding.
Tuling Flexible Busbar Design Considerations
Our flexible copper bar is made from stacked layers of thin tinned-copper. It is insulated with a high-resistance and self-extinguishing compound. Our design considerations are,
- Hole: We keep a minimum 3/16’’ distance between the flexible edge to the nearest edge.
- Bending Radii: Our bending radius is > = 1/2’’. Ideally, we keep a bend radius equals to 1/8’’x number of laminates.
- Length: Twisting length of our busbars is at least three times the width.
- Twisting: Our designs allow the busbar not to twist greater than 90 degrees.
- Punching: We drill or punch holes directly on the copper laminates.
Tuling Flexible Busbar Usage
Our flexible busbars suit a variety of applications. Such as,
- Rail Connection: Traditional bulky cables do not fit the tight spaces of the next-generation onboard rail power system. Tuling flexible bus bars consume less space, provide better performance, and confirm safety.
- Data Center: Tuling bus bars can efficiently distribute power to cabinets and busways. It reduces the risk of signal loss and power disruption in the internet and cloud services.
- Renewable Energy: Our flexible busbars can connect energy sources, such as solar panels and wind turbines, to inverters and grids without power loss.
- Automotive: Flexible busbars safely connect several components in the BMU and distribute high power to different subcomponents. These also ensure efficient power transmission in the charging system.
Flexibility requirements, current carrying capacity, and thermal performance are the most important considerations while choosing a flexible busbar. Besides, you need to keep in mind the mechanical strength, durability, environmental need, and industry standards to select the right busbar for your application.
Tuling flexible busbars consume less space and weigh less than the traditional busbars. Besides, our busbars require no lugs for a secure installation. As we use high conductive copper and aluminum, our flexible busbars can transmit power more efficiently.
Mechanical fasteners, e.g., bolts and screws, are used to install the flexible busbars to the mounting surface. You can punch the bolts directly through the bus bar laminate to establish a secure connection.
