Bent and Punched Busbars

Name: Bent and Punched Busbars | Shaped and Drilled Busbars | Custom Formed Busbars - Frigate
Price: 249.00 USD
Availability: InStock

Tight enclosures and compact systems demand innovative solutions. Bent and punched busbars eliminate the need for bulky cable assemblies by providing a streamlined, space-efficient design. These busbars are custom-shaped to fit snugly into tight spaces, reducing system volume without compromising current-carrying capacity. Their adaptability enables seamless integration into complex layouts, ensuring that every inch of your enclosure is utilized efficiently.

Material Core

Copper, Aluminum, Brass, or custom alloys

Tin Coating Thickness

3-15 microns (depending on material and application)

Bus Bar Thickness

1-10 mm (customizable based on requirements)

Bus Bar Width

10-100 mm (customizable based on system design)

Electrical Conductivity

Copper: 58-60 MS/m; Aluminum: 35-37 MS/m

Product Description

Excessive heat in power systems can lead to energy losses and damage. Bent and punched busbars excel in thermal management. Their flat, conductive surfaces provide superior heat dissipation to traditional cables, reducing hotspots and improving system longevity. This capability increases efficiency and minimizes the risk of Komponente failure due to overheating.

Thermal Conductivity

Copper: 398 W/m·K; Aluminum: 237 W/m·K

Voltage Rating

Up to 1000 V (customizable for higher ratings)

Current Rating

50-2000 A (customized based on design and application)

Operating Temperature

-40°C to 120°C (can be adjusted for specialized applications)

Corrosion Resistance

High resistance to oxidation, corrosion, and galvanic corrosion (depending on coating)

Mechanical Strength

Yield Strength: Copper 210 MPa, Aluminum 150 MPa

Plating Adhesion

> 3.5 N/mm (according to ASTM B571-96)

Surface Finish

Matte, Glossy, or custom finish based on application

Customization Options

Custom bends, hole placements, material selection, coating types, and dimensions

Standards Compliance

UL, IEC, RoHS, ASTM, ISO, and custom industry standards

Technical Advantages

Every watt counts in modern power systems. These busbars offer low electrical resistance, significantly reducing power losses compared to round cables. With optimized punched patterns, they distribute current uniformly, eliminating bottlenecks and ensuring maximum efficiency even in high-power applications.

Traditional wiring assemblies are often labor-intensive and prone to errors during installation. Bent and punched busbars are pre-engineered for quick assembly, reducing installation time and ensuring error-free connections. This pre-fabricated precision simplifies maintenance by offering clear, easily accessible points for testing and inspection, helping you minimize downtime.

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Industry Applications

High-Voltage Electrical Systems

Used for precise current distribution in high-voltage equipment like circuit breakers and bus ducts.

Motor Control Centers

Provide efficient power distribution and connectivity for large motors and associated control devices.

Uninterruptible Power Supplies (UPS)

Ensure reliable and efficient power transfer between batteries and load in critical power backup systems.

Electric Power Conversion Systems

Integral in power electronics, enabling efficient current handling in inverters and rectifiers.

Capacitor Banks

Facilitate power factor correction by efficiently distributing current in reactive power compensation units.

Fuel Cells

Used in hydrogen and fuel cell systems to ensure high-current reliability and minimize voltage drops.

Durability and Customization for Extreme Conditions

Electrical systems in industrial or outdoor settings must endure extreme conditions. Our busbars are crafted from high-grade materials like copper and aluminum, often coated with protective layers to resist corrosion, oxidation, and mechanical wear. This ensures long-lasting performance in demanding environments, from heavy industry to renewable energy installations.

Off-the-shelf solutions don’t always meet the needs of specialized systems. Bent and punched busbars are highly customizable to your specifications, whether unique bends, hole placements, or material choices. This versatility ensures compatibility with your design requirements and compliance with industry standards.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How do bent and punched busbars improve current flow in high-power applications?

Bent and punched busbars, due to their flat, wide surfaces, provide a low-resistance path for electrical current. This design minimizes resistance compared to traditional round cables. Punched holes allow for precise connections, reducing contact resistance at junction points. The result is a more efficient current distribution, especially in high-power systems where consistent performance is critical.

What role does punching play in the thermal management of busbars?

Punching in busbars is not just for mounting or connections—it also aids in thermal dissipation. The holes act as heat relief points, allowing better air circulation around the bar. Combined with the flat geometry, this design ensures uniform heat distribution and faster cooling, preventing thermal hotspots even under heavy electrical loads.

Can bent busbars reduce electromagnetic interference (EMI) in electrical systems?

Yes, bent busbars help reduce EMI by maintaining tighter control over current paths. Unlike loose wiring, their compact and uniform design minimizes stray magnetic fields, which can cause variable inductance. Proper bending and strategic placement ensure the busbar system aligns with EMI shielding requirements in sensitive applications.

How does material choice affect the performance of bent and punched busbars?

The choice of materials heavily influences the performance of busbars. Copper provides excellent electrical conductivity, making it ideal for high-current applications, while aluminum is lightweight and cost-effective for moderate loads. Protective coatings like tin, silver, or epoxy enhance resistance to corrosion and oxidation, ensuring reliable performance in harsh environments.

What is the impact of precision bending on mechanical stress in busbars?

Precision bending ensures that busbars pflegen structural integrity even under mechanical and thermal stress. Accurate bends reduce stress concentrations at critical points, preventing cracking or deformation over time. This precision also ensures a snug fit in enclosures, reducing vibration and wear caused by loose connections in dynamic environments.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Bent and Punched Busbars

Material Core

Tin Coating Thickness

Bus Bar Thickness

Bus Bar Width

Electrical Conductivity

Product Description

Thermal Conductivity

Voltage Rating

Current Rating

Operating Temperature

Corrosion Resistance

Mechanical Strength

Plating Adhesion

Surface Finish

Customization Options

Standards Compliance

Technical Advantages

Let's Get Started

Industry Applications

Durability and Customization for Extreme Conditions

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Bent and Punched Busbars

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