Flat Copper Busbar
Efficient, Compact, and Highly Conductive Copper Connections
Our flat copper busbar is the core component of DC power distribution systems in copper SX-EW and electrorefining tankhouses. Manufactured from high-purity T2 copper, it delivers ultra-low resistivity, minimal voltage drop and reliable long-term performance under high-amperage (10–48 kA) operating conditions. We provide complete custom fabrication services to match your exact tankhouse layout and electrical requirements.
High-Conductivity Power Distribution for Copper Electrowinning Tankhouses
Material & Structural Design
- Base Material: High-purity T2 copper (ASTM C11000 / ISO Cu-ETP)
- Copper Purity: ≥99.90% (oxygen content ≤0.003%)
- Standard Shapes: Rectangular flat bar, square bar, round bar
- Surface Finish: Mill finish / CNC machined flat contact surfaces (Ra ≤1.6μm)
- Structural Features: Uniform grain structure, excellent mechanical strength and dimensional stability
Core Electrical Performance
- Electrical Conductivity: ≥97% IACS (International Annealed Copper Standard)
- Electrical Resistivity: ≤0.017241 Ω·mm²/m at 20°C
- Temperature Coefficient of Resistance: 0.00393 /°C
- Maximum Continuous Operating Temperature: 105°C
- Current Carrying Capacity: Up to 5 A/mm² (ambient temperature 30°C)
Technical Specifications
| Item | Specification |
|---|---|
| Material Grade | T2 Pure Copper / ASTM C11000 |
| Copper Purity | ≥99.90% |
| Conductivity | ≥97% IACS |
| Standard Thickness Range | 3 mm – 120 mm |
| Standard Width Range | 10 mm – 1000 mm |
| Standard Length | Up to 6000 mm (custom lengths available) |
| Tolerance | Thickness: ±0.05 mm; Width: ±0.1 mm; Length: ±1 mm |
| Surface Roughness | Ra ≤1.6μm (machined contact surfaces) |
Standard Current Rating Table
| Cross Section (mm²) | Recommended Current (A) | Typical Application |
|---|---|---|
| 100×10 | 5000 | Inter-cell connectors |
| 150×10 | 7500 | Anode/cathode busbars |
| 200×12 | 12000 | Main DC busbar segments |
| 300×15 | 22500 | Rectifier output busbars |
| 400×20 | 40000 | Large-scale tankhouse main bus |
Product Advantages
Space-Saving Layouts: Flat copper bars allow compact installations in high-current setups like electrowinning cells or control panels.
Thermal Management: High conductivity ensures lower heat generation and efficient current flow.
Easy Termination: Flat bars offer more surface area for connections, allowing stable bolt, weld, or press-fit contacts.
Custom Machining: PRS provides drilled, bent, or punched copper bars to meet project-specific needs.
Surface Options: Tin or silver plating improves corrosion resistance and solderability in humid or acidic environments.
Customization Capabilities
- Custom dimensions, thicknesses and lengths
- Special shapes and bent configurations
- Precision drilled holes and slot patterns
- Tin plating, silver plating or nickel plating surface treatments
- Pre-assembled busbar segments with connection hardware
- Complete tankhouse busbar layout design services
Dimension Matching: Busbar size must align with equipment bus duct or connector layout. We offer technical drawings and pre-production samples to verify before mass production.
Thermal Rating: Customers often underestimate temperature rise - PRS offers current carrying capacity calculations per IEC standards to support safe design.
Logistics of Long Lengths: Copper is heavy and costly to ship - our team can suggest optimal length and packaging strategy to minimize freight and customs duty.
Surface Finishing Preferences: Whether tinned or bare - pls. clarify when ordering to avoid post-production delays.
Bolt Hole Positioning: If required, please provide exact hole diameter and spacing drawings or CAD files.
Packaging & Transportation
Bundled with anti-oxidation paper and shrink wrap.
Palletized with wooden reinforcement or crate (export-grade).
Each batch is labeled with part number, batch code, and dimensions.
Optional copper bar end protection caps to avoid edge damage during transit.
FAQ
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