Busbar insulation line
High-precision extrusion technology for aluminum and copper busbar insulation
Extrusion technology for busbar insulation
Our busbar insulation line is designed for the continuous insulation of aluminum or copper busbars used in electric vehicles, battery systems, and other high-voltage applications. The integrated extrusion process combines precise conductor preparation, stable extrusion, and optimized cooling to deliver repeatable product quality.
The high-end busbar extrusion line delivers the precision and process stability required for automotive applications.
Your Rosendahl benefits:
- Repeatable quality
- High process stability
- Automated, scrap-saving production
Supporting next-generation mobility
Produce busbars with strong product properties
Firm adhesion of the insulation layer
Uniform wall thickness
Mechanical strength
Excellent bending and torsion behavior
The busbar extrusion process
Processing busbars is more challenging compared to cables with round cross-sections. High-quality busbar insulation is the result of a precisely controlled extrusion process. Together with precise conductor guiding, careful take-up, and real-time process monitoring through RIO Line Control, these steps ensure stable production and repeatable product quality:
Conductor pre-treatment
Before extrusion, the wire is carefully aligned, cleaned, and preheated. This preparation is essential to ensure proper insulation adhesion and to achieve the required product geometry.
Precision extrusion
Our ROEX extruder technology and RX crosshead form a perfectly matched extrusion system, ensuring stable melt flow, precise insulation application, and uniform wall thickness throughout production.
Optimized cooling
Proper cooling is crucial for achieving the desired level of adhesion. We have optimized the cooling process to bring out the best insulation properties in busbars for demanding automotive applications.
Busbar insulation line highlights
Technical data
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Geared line speed 150 m/min
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Conductor materials Al, Cu
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Conductor cross-section 25 – 300 mm²
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Insulation materials PVC, PA, TPE/TPV, PPS
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Wall thickness 0.50 – 2 mm
Mastering busbar insulation since 2011
With many years of experience in handling flat cables, we are your reliable solution provider for this demanding product.
Busbar FAQs
Flat conductors have a larger surface area, making thorough cleaning immediately before extrusion particularly important. Removing contaminants from the conductor surface ensures strong adhesion between the insulation material and the busbar, which is essential for reliable product performance.
Depending on the application requirements, various insulation materials can be used. Typical materials include PVC, PA, TPE/TPV, PPS, with PA12 currently being the most commonly requested for automotive applications.
Controlled cooling helps develop the desired insulation properties while maintaining excellent adhesion and uniform wall thickness throughout the product.
Key quality characteristics include strong insulation adhesion, uniform wall thickness, accurate product geometry, high mechanical strength, excellent bending and torsion behavior, and reliable insulation adhesion after bending.
The Rosendahl busbar insulation line combines precise conductor guiding, optimized conductor preparation, stable extrusion technology, controlled cooling, and careful product handling to achieve repeatable production results. A robust portal take-up gently winds the busbars layer by layer with precise spacing. Integrated RIO line control provides real-time process monitoring and maximizes overall productivity.
Unlike round cables, rectangular busbars require highly accurate guiding and process control. Even small deviations can affect insulation thickness, adhesion, and overall product quality. In addition, the larger surface area of flat conductors makes thorough cleaning immediately before extrusion essential to ensure strong insulation adhesion and consistent product performance.
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let's discuss your busbar production
Share your production requirements, and we’ll help you configure the ideal line for your application.
