Ensuring efficient connections between components is crucial in the design and operation of electrical systems, and copper bars are an indispensable component. They are widely used in low-voltage complete sets of equipment as transmission media for current. However, to ensure the safety and efficiency of these copper bars during use, their surfaces must be appropriately protected. This is because bare copper bars are prone to oxidation when exposed to air, which not only reduces their conductivity but also shortens the lifespan of the equipment.

Why is bare copper busbar widely used in switchgear?

In fact, the use of bare copper bars not only meets basic electrical safety requirements in a good environment, but also demonstrates its excellent performance advantages. By applying bolts of appropriate specifications and precise torque to tighten, the overlapping surface of bare copper bars can effectively avoid direct contact with air and moisture, thereby preventing the formation of oxide layers. This approach also ensures a tight fit between the copper bars, maintaining contact resistance at a low level, which is crucial for operational safety.

Furthermore, although bare copper bars gradually form an oxide layer in the air, the characteristics of this oxide layer actually provide additional protection for the copper bars. Especially in the high-temperature environment of low-voltage equipment, the thin film like oxide layer rapidly formed on the surface of the copper busbar can effectively block further oxidation of the internal copper busbar and maintain its excellent conductivity. It is worth mentioning that the heat dissipation capacity of copper oxide far exceeds that of untreated bare copper, about 14 times higher. Due to the fact that about 15% of the heat generated by copper bars is dissipated through radiation, the formation of an oxide layer significantly improves the heat dissipation efficiency of bare copper bars, thereby optimizing their current carrying performance.

Why do we need surface treatment

However, copper oxide is almost non-conductive because it has no free electrons and ions that can move. Before installation, it is necessary to check whether there is oxidation on the copper bars. If there are any signs of oxidation, immediate measures should be taken to remove these oxides. This step usually involves physical or chemical methods to ensure the purity of the copper bar surface. For example, methods such as acid washing and chemical deposition are commonly used to passivate the surface of copper bars, forming a protective film on them to effectively prevent further oxidation.

What are the common surface treatments in 03

According to different application environments and requirements, the surface of copper bars may require additional treatment, especially at the junction of copper bars. For example, tin plating, nickel plating, silver plating, and insulation treatment are common surface treatment methods. These treatments not only provide better anti-corrosion effects, but also improve the electrical performance and mechanical strength of copper bars. Especially tin plating treatment, it not only provides good corrosion resistance, but also reduces the contact resistance on the surface of copper bars to a certain extent.

The surface treatment of copper bars is a complex but crucial process. By adopting appropriate processing methods and techniques, the performance and reliability of copper bars can be significantly improved. Whether through passivation, coating, or other methods, proper surface treatment can ensure that copper bars can perform at their best in various environments, while extending the overall lifespan of the equipment.

04 Choose the appropriate surface treatment

In the power system, copper bars are important conductive components, and their surface treatment technology is crucial for the stability and efficiency of the system. Among them, the nickel plating treatment of copper bars not only significantly improves their corrosion resistance and oxidation resistance, but also enhances their adhesion and wear resistance due to their high hardness. This makes nickel plated copper bars particularly suitable for applications that require frequent sliding connections, such as primary connectors for drawer cabinets and contact points for vertical busbars. In addition, nickel plating can give copper bars a brighter appearance, improve aesthetics, and extend service life.

On the other hand, the silver plating treatment of copper bars is mainly aimed at improving their conductivity. By silver plating, the contact resistance of copper bars can be effectively reduced, thereby improving the overall conductivity efficiency. Due to the extremely high chemical stability of silver, this treatment also enables copper bars to maintain good performance in various environments. However, considering cost factors, this processing method is usually applied to component terminals with extremely high requirements for conductivity, or used on copper bar overlap surfaces that pursue optimal temperature rise performance. Of course, in some cases, financially strong homeowners may also choose this high-end approach based on personal preferences.

Why do most copper bars undergo insulation treatment

As for the insulation treatment of copper bars, its main purpose is to enhance the electrical isolation between copper bars and ensure safe operation. Common insulation treatment methods include epoxy resin spraying and covering with heat shrink tubing. Although these methods can effectively improve insulation performance, they also increase the difficulty and cost of processing technology. Many experienced electricians tend to use heat shrink tubing because it not only provides good insulation performance, but also increases operational safety to a certain extent.

Summary of Surface Treatment of 06 Copper Bar

According to different working environments, copper bars require different surface treatment methods. Although these surface treatments bring an increase in cost, they can improve the performance of copper bars in certain aspects. But at the same time, it may also sacrifice other abilities. For example, nickel plating or using heat shrink tubing for comprehensive insulation treatment can reduce the heat dissipation capacity of copper bars, thereby affecting their current carrying capacity. When choosing whether to perform surface treatment on the copper bars or maintain the bare copper state, the technical disclosure between the disk factory and the party A must clarify this point. The cabinet products themselves offer multiple options, but there is no particular preference for one method. Bare copper bars can be used in any switchgear, unless there are special environmental and location requirements. It is recommended to use bare copper bars to save costs.

Article source: Lithium Battery Industry