As a key conductive material in power systems, copper busbars, thanks to their excellent conductivity, mechanical strength, and corrosion resistance, are widely used in power distribution systems such as substations, switchgear, and large industrial equipment. Their core function is to ensure efficient and stable power transmission under high current conditions, making them a crucial infrastructure for the safe operation of power grids.
In terms of material properties, copper has a resistivity of only 1.68×10⁻⁸ Ω·m (at 20°C), significantly lower than other common conductors such as aluminum. This results in copper busbars generating less Joule heating when transmitting the same current, effectively reducing energy loss. Furthermore, copper's high ductility and tensile strength (approximately 200-300 MPa) enable it to withstand mechanical stress and adapt to complex installation environments. Furthermore, the dense oxide layer formed on the copper surface retards further corrosion, maintaining long-term stability in humid and chemical environments.
In practical applications, copper busbars typically adopt rectangular, slotted, or tubular designs to optimize current distribution and minimize the impact of the skin effect. For example, tubular busbars used in high-voltage substations reduce eddy current losses through their hollow core structure, while multi-layer copper busbars are suitable for high-current distribution cabinets. To further enhance performance, copper busbars are silver-plated or tin-coated in some scenarios to reduce contact resistance and enhance oxidation resistance.
As power systems evolve toward higher voltages and higher capacities, copper busbar technology is accelerating. In the future, by optimizing alloy composition (such as adding trace amounts of rare earth elements) and employing advanced processes like laser welding, the current-carrying efficiency and reliability of copper busbars will be further enhanced, providing continued solid support for global energy networks.
