High Current Flexible Busbar Manufacturer – Yanghua Cable
When you need a custom high current flexible busbar for power distribution, Yanghua Cable (Yanghuasti) supplies UL-recognized, single-insulated flexible busbars rated up to 3000 A, in widths from 20 to 300 mm, with lengths up to 3000 mm [K1]. These busbars are cut to size, drilled, and tinned for bolted connections, making them a direct alternative to traditional copper cables in heavy electrical systems.
Application Scenario
Yanghua flexible busbars serve as a compact, high-current busbar solution in enclosed power distribution equipment—including switchgear, panel boards, busways, and control cabinets [K1]. Their thin, flat profile (typically 0.3–1.0 mm per layer) allows for efficient current flow and heat dissipation in constrained spaces. Typical voltage ratings cover 600 V to 1000 V AC/DC, depending on insulation [K1].
Engineering Decision Criteria
| Criteria | Yanghua Flexible Busbar (Single-Insulated) |
|---|---|
| Current rating | Up to 3000 A [K1] |
| Busbar width | 20–300 mm [K1] |
| Busbar length | ≤ 3000 mm [K1] |
| Insulation | Single polyester/film wrap (UL 94 V-0 rated) [K1] |
| Connections | Tinned ends, bolted joints [K1] |
| Custom services | Cutting, drilling, tinning [K1] |
| Typical use | Enclosed distribution panels, battery racks |
Key engineering judgments from source [K1]:
- Flat conductor geometry reduces skin effect at high frequencies.
- Laminated structure provides mechanical flexibility.
- Copper foil layers are available in multiple thicknesses.
Suitable / Not Suitable Cases
Suitable:
- High-density power distribution in switchgear panels where space is tight.
- Battery-to-inverter connections in energy storage systems (single insulated).
- Bus bar replacement for copper cables in retrofit upgrades.
Not suitable:
- Outdoor or moisture-exposed applications (single insulation is not weatherproof; specify double insulation).
- Applications requiring direct burial or contact with corrosive chemicals.
- Continuous bending or dynamic flexing (busbar is for static installation only).
Procurement Notes
To proceed with ordering a custom flexible busbar from Yanghua:
- Specify current rating (A), width (mm), length (mm), and hole pattern.
- Confirm insulation type: single wrap for indoor, double wrap for higher isolation [K1].
- Request tinning of terminal ends for corrosion resistance and low contact resistance.
- Lead times vary by custom work; contact Yanghua for current production schedule.
FAQ
Q: Can these busbars carry 3000 A continuously in a 40°C ambient?
A: The source material states maximum 3000 A rating, but de-rating applies based on enclosure ventilation, conductor cross-section, and allowable temperature rise. Consult Yanghua for your specific enclosure thermal model.
Q: What is the minimum bending radius for a 100 mm wide busbar?
A: Flexible busbars can be formed manually; however, repeated bending may crack insulation. Yanghua recommends custom pre-formed shapes for production orders.
Q: Are UL or CE certifications available?
A: Yanghua lists UL recognition on the material components; confirm current certifications for your region with the sales team before ordering.
Q: Do you supply double-insulated versions for safety-critical systems?
A: Yes, double-insulation options are available—verify with Yanghua for the specific insulation grade and dielectric strength.
Q: How is the busbar terminated for battery lugs?
A: Tin-plated copper ends with pre-drilled holes to match standard terminal bolts. Provide a hole pattern diagram with your order.
About the Author Yanghua Engineering Team — 15+ years of flexible busbar design, manufacturing, and project delivery for energy storage, solar PV, EV charging, and industrial electrification.
The team holds a VDE flexible industrial cable training certificate (2024) and operates an in-house R&D Experimental Center. Yanghua flexible busbar products have passed type testing with official test reports.
Contact: info@yhflexiblebusbar.com | Hotline: 400-883-1383