Epoxy-Insulated Power Transmission Gear
Epoxy-coated busbars improve safety without increasing
operating temperature – according to recent testing at SolEpoxy labs. Bare bars
were tested side-by-side with bus bars coated in epoxy, wrapped in mylar, and
surrounded by polyolephin shrinktube.
As expected, the mylar
and shrinktube-wraped bus bars cooled down more slowly than did bare copper and
Surprisingly, epoxy-coated copper bus bars cooled just as
fast as bare copper. Bare aluminum cooled only slightly faster than
This test demonstrated that DK15-0907, UL-listed epoxy
composite, yields electrical insulation without sacrificing heat transfer.
We gathered data in Figure 1 using bars coated with 1.5mm of
epoxy -- sufficient to insulate 15 kV. Low voltage busbars – typically 600V,
and used for power distribution in large buildings, require less than 0.5mm of Epoxy
for a tough, durable electrical insulation. At this thickness, we found a
Fusion Bonded Epoxy
May Actually Improve Heat Transfer
In a separate
experiment, we compared cooling rate as a function of epoxy coating thickness.
The graphs above depict the results, with the black lines representing cool down time of bare bar in both graphs. Thin epoxy – approximately 0.5mm, actually
improved heat transfer from both Copper and Aluminum busbars! We are still
experimenting but we suspect that the fusion-bonded epoxy may improve
emissivity. Red and black epoxy performed about the same. A gloss finish
performed just as well as a flat finish.
Epoxy-coated busbars can provide improved safety without
substantially effecting heat transfer from the conductors. This is an important
insight for engineers who are designing the future around e-mobility,
micro-grids, and the electrification of everything. To keep up with insulation
trends, contact SolEpoxy for by emailing firstname.lastname@example.org
or calling (716)-372-6300.