Bus bar in the image above shows an example of combined epoxy powder coating and "boot" insulation inside a generator enclosure.

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		Storm Copper offers several insulating material and plating options for powder-coated and other types of insulated bus bar. Please feel to download a PDF that gives an in depth look at these options and more. Insulated Bus Bar PDF

Epoxy Powder-Coated Bus Bar Insulation

Electrostatic-Spray and Fluidized Bed Powder Coating - UNDER ONE ROOF.

Storm Copper has the expertise, capabilities and equipment to manufacture high dielectric, epoxy powder-coated bus bar for OEMs in need of insulated copper conductors for tight-fitting, durable bus systems. 

Epoxy Powder-Coated Insulation allows for closer component location in a system, which is ideal for single conductors or multiple conductor assemblies that may have numerous forms.  Epoxy powder coating is also well suited for insulating thick conductors, in addition to conductors with multiple electrical contact points. The material also has a high dielectric strength and is a durable insulator, impervious to most elements.

About the material... Epoxy powder coating is a free-flowing, thermosetting dry powder. Think of this process as a way of "melting" paint over a copper or plated copper surface to create a durable, protective surface with thickness ranging from of 6 to 120 mils or .006 to .120 inches. When the epoxy powder cures, a cross-link occurs increasing molecular weight and insulation capability.  Insulation. Insulation. Insulation... Epoxy powder is chemical resistant and one of the oldest powder paints used in the electronics industry. It not only protects against corrosion but carries a high insulation rating of 800 to 1200 volts per mil (.001 inches). Tensile strength on raw and plated copper bar is in the range of 7500 PSI. UL rating is 130 Cº. Epoxy powder coating's high dielectric strength can be varied based on the application process and component preparation. Storm Copper offers the following standard colors for quick pricing and delivery. Spray Coatings: Blue, Gray, Red and Black. (Green available soon.) Fluid Bed Coatings: Red and Black. (More available soon.) Storm Copper conducts four component preparation processes prior to applying the powder coating: Cleaning - Storm's bare or plated copper bar has already gone through a vigorous multi-step cleaning cycle.  Yet we conduct a final cleaning process prior to coating to remove all contaminants.  Edge Conditioning - Finished edges and burr removal promote uniform epoxy powder coating for consistent dielectric strength, and may include hand sanding, small part tumbling, and if required, a machined radius. Masking - Surfaces that do not require powder coating are masked with high temperature tape. Masking is applied to each location and remains on the part until after the curing cycle. Location of the mask is a manual operation, and a liberal tolerance is recommended. If location is critical, a line will be scribed on the conductor for more precise positioning.  Pre-Heating - Storm preheats bus bars and other copper parts to enable the epoxy powder to melt, creating a sticky film that picks up more powder, quickly and evenly.   Dielectric strength is based on volts/mils, but tensile strength depends on the amount of powder-coat applied, component preparation and design considerations. (see below) Epoxy Powder-Coat Applications - Electrostatic Spray or Fluidized Bed? The choice between electrostatic spraying or fluidized bed powder coated is determined by the dielectric strength of a copper component. The general rule of thumb is that high-voltage bar should be fluid dipped to achieve a thickness greater than .12 inches. Size and shape also play a part. Bus bars or other components with flat, open geometry are more suitable for spraying, while components with turns and bends are better suited for fluidized be powder coating.

Electrostatic Spray Before the epoxy powder is sprayed onto the part, Storm conducts a set up procedure to determine the amount of powder deposited, which is controlled by voltage, airflow and powder flow. Next this electrostatic system imparts a negative electric charge on the powder to deposit it onto the component that has been grounded.  Component(s) are then placed in Storm's curing oven that has the capacity to handle parts up to 12’ in length. As the thermo set powder is heated, it begins to melt and flow out, enabling it to form a higher molecular weight polymer fusing both to itself and the substrate.

Fluidized Bed Epoxy powder is suspended by air that is pumped into a sealed chamber and through a porous plate into an aerated hopper where the powder floats in a fluidized state. Then heated copper connectors are lowered into the hopper, causing the powder to adhere to the surface and then flow out. This creates a smooth, durable and continuous epoxy coating that is thicker than the coating on sprayed copper components. As with sprayed components, coated parts are sent to a curing oven.

Design Considerations - Please consider the following guidelines when detailing your design:

Storm Copper sprays epoxy coatings thickness in the 6- to 12-mil range.  Please keep this in mind, especially when specifying thru hole diameters. Fluidized bed coverage is in the range of 10 to 60 mils.

The larger the bend radius the better - if allowable.  This will help the powder flow  more smoothly without build-up or thinning. Also, try to avoid small cutouts in the conductor, as they are more difficult to edge condition and could create areas for test failure. Always dimension designs to the substrate, not the powder surface. And remember to carefully consider masking location tolerances.

Testing Criteria - A Hi-Pot test is performed to make sure the finished coating has no defects such as pin holes, voids and thin areas near sharp corners or edges. All surfaces will be scanned at twice the operating voltage plus 1,000 volts as standard procedure, unless otherwise specified.  For example, if the operating voltage is 700v,  Storm will test at 2400v. Storm currently tests up to 14000 volts.

 

Epoxy powder coating emits near zero VOC and over spray can be recycled.