POWER
Powder Coated Bus Bars for Durability and Reliability
Powder coatings are an efficient method for insulating electrical and electronic components, offering a solid, protective layer that enhances the electrical insulation properties of various parts, such as busbars, transformers, motors and connectors.
T
hese coatings are applied as a free-flowing, dry powder that is electrostatically charged and then cured under heat to form a smooth, hard finish. Powder coatings provide excellent dielectric properties, making them ideal for insulating electrical or electronic components. The absence of solvents also reduces the risk of harmful emissions during application, making powder coatings environmentally friendly. Additionally, they offer high resistance to corrosion, heat and moisture, which are critical for subcomponents operating in harsh environments. Compared to other coating methods such as liquid coatings and varnishes, powder coatings stand out for their durability and eco-friendliness. Liquid coatings, while effective, often require the use of volatile organic compounds (VOCs), which can be harmful to both workers and the environment. Moreover, liquid coatings may require multiple layers and longer curing times, leading to increased production costs. Varnishes, often used in electrical insulation, provide a protective layer but may not offer the same level of corrosion or heat resistance as powder coatings. Additionally, varnishes can be prone to cracking over time, especially in
high-temperature applications, whereas powder coatings provide a more uniform and robust finish. Overall, powder coatings offer superior performance in terms of durability, insulation and environmental impact when compared to other methods.
Highly Demanding Applications Powder coatings are increasingly being applied to a variety of electrical and electronic subcomponents to enhance their durability, insulation and environmental resistance. Subcomponents, such as bus bars, often face high demands for performance under extreme conditions, making powder coatings a key technology for improving their reliability and longevity in military use and increasingly in rigorous industrial or
utility applications. Bus bars are traditionally used for high-voltage power distribution in vehicles, aircraft and naval systems. Bus bars benefit from powder coatings for insulation and protection against corrosion, vibrations and mechanical stress. In critical applications, such as power distribution and electronic/electrical infrastructure, bus bars are increasingly replacing traditional wiring due to their efficiency in conducting electricity at high voltages while maintaining a compact form factor. Bus bars, made of copper or aluminum, offer superior electrical conductivity, especially in environments where space is limited and electrical loads are high. To enhance performance and longevity in challenging conditions, powder coatings have emerged as a key technology. These coatings not only improve the durability of bus bars but also provide insulation, corrosion resistance and protection from environmental factors, including vibrations and mechanical stresses. Enhanced Insulation: In high-voltage systems, insulation is paramount to prevent short circuits and electrical failures. Powder coatings ensure that even in applications with fluctuating or high voltage levels, the bus bars are adequately insulated, reducing the risk of electrical failures and improving system safety.
Resistance to Vibrations and Mechanical 38 NOVEMBER 2024 | ELECTRONICS FOR ENGINEERS
Stress: One of the key advantages of powder coatings is their ability to withstand vibrations and mechanical stress, which are common in industrial and transportation environments, such as rail systems, electric vehicles and aerospace.
Corrosion and Environmental Protection: Bus bars are often exposed to harsh environmental conditions, including humidity, chemicals and extreme temperatures, which can lead to corrosion and reduced conductivity. Powder coatings are highly resistant to corrosion and oxidation, protecting the metal surfaces of bus bars from environmental damage. Compact and Lightweight Designs: Space and weight are often at a premium in military and commercial systems, especially in vehicles and aircraft. Bus bars and subcomponents, particularly those with powder coatings, allow for more compact and lightweight electrical distribution systems compared to traditional approaches.
By: Carol Brower, Michael Schulte, Pradeep Haldar
Custom Electronics, Inc., Oneonta, New York
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