Low Presssure Injection Copper Busbar

01-Introduction of Copper Busbar Low Voltage Injection Molding

Ø A process that combines copper busbars with low-pressure injection molding technology. Low pressure injection molding is a method of injecting packaging material into a mold at a lower injection pressure (about 1.5-40 bar) and rapidly curing it into target shape (5-50 seconds)

Ø This technology is mainly used for packaging and protecting precision and sensitive electronic components, such as printed circuit boards (PCBs), automotive electronic products, mobile phone batteries, wiring harnesses, waterproof connectors, sensors, etc

02-Advantages of Low Voltage Injection Molding for Copper Busbar

Ø Low pressure injection: reduces damage to copper bars and improves yield

Ø Rapid curing: Shorten production cycle and improve production efficiency

Ø Environmentally friendly materials: The hot melt adhesive used meets environmental standards and is non-toxic and harmless

Ø Multifunctionality: Provides multiple protections such as insulation, moisture resistance, waterproofing, dust prevention, and chemical corrosion resistance

03-Advantages of Low Pressure Injection Molding Material-PA646（TECHNOMELT-Henkel）

Ø Easy to mold

Ø Has good adhesion to various substrates

Ø Excellent moisture resistance ability

Ø Excellent environmental resistance ability

Ø Simplify the process flow

Ø Especially suitable for applications that require high strength and hardness

04-Application Fields

Ø Low voltage injection molding of copper bars is mainly used in the manufacturing of electrical equipment, especially in situations where high conductivity and structural strength are required

Ø For example, in power transmission and distribution systems, copper bars are used as conductive components and can be better fixed and protected through low-voltage injection molding technology, while providing insulation and protection functions. This process has significant advantages in electrical equipment manufacturing, as it can improve the reliability and safety of the equipment

05 Manufacturing Process flow

Ø Preparation stage: Select suitable copper bars and low-voltage injection molding materials to ensure that the conductivity and insulation properties of the materials meet the requirements

Ø Mold design: Design a mold that is suitable for the shape and size of the copper bar, ensuring that the copper bar can be firmly fixed in the mold

Ø Injection molding process: Molten plastic is injected into the mold and injected around the copper bars. Low injection pressure to avoid damage to copper bars

Ø Solidification molding: By rapid cooling and solidification, a sturdy plastic shell is formed to wrap and protect the copper bars

Ø Post processing: Necessary trimming and testing of the formed components to ensure product quality