The Future For Busbars

Manufacturing costs are a growing concern in the search for a more cost effective environment. For manufacturers of electrical components, changing times mean that they need to adapt their materials to meet environmental demands.

Busbar power distribution units are growing in popularity as they become more sophisticated and versatile.

 A busbar is a metallic bar that acts as an electrical conductor, carrying large currents and distributing electricity from a switchboard. They are strong and durable, able to withstand the most extreme weather conditions, temperature changes and magnetic variations caused by large amounts of electricity.

A busbar is contained within a panel board. Its purpose is to safely allow other electrical conductors to connect, making a common connection between several circuits.

Traditionally, copper has been used for decades in the electrical industry because of its high conductivity and durability. However, copper prices are soaring and other materials are now being sought as alternatives.

ALUMINIUM 

Aluminium is fast replacing copper as a more cost effective material in the manufacture of busbars. Up to 70% lighter than copper, aluminium is a favourite with the marine and aerospace industries where weight is a serious factor. With lower transportation, labour and installation costs, aluminium has a much lower carbon footprint than copper. It doesn’t spark when coming into contact with other metals, posing less danger in inflammable environments. It’s non-magnetic properties are an added benefit.

Aluminium does not conduct electricity as well as copper, but its cost effectiveness means that it is a more feasible material for the future. With the expansion of the electronic hybrid motor industry, aluminium busbars are a popular choice for vehicle manufacturers. Mercedes-Benz already uses busbars in its Bluetec hybrid models.

CUPONAL

With the need for more cost effective materials, many manufacturers use cuponal busbars. Cuponal is a mix between aluminium and copper. It is a copper clad, aluminium bi-metal conductor. Cheaper than copper, it is lightweight like aluminium, yet with the same conductive efficiency as copper. The copper insulated layer gives a cuponal busbar more flexibility so it can be easily manipulated and formed

Its lower weight means that it’s easier to handle, punch and bend. Its freight costs are considerably lower than copper, making it a better economic alternative for consumers.

HV Wooding is a leading global manufacturer of precision engineered electrical components using state-of-the-art technology in providing busbars to the marine, aerospace and motor industries, among others. Contact us today for more information.