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Busbars
CCT manufactures a complete range of busbar solutions for power distribution, energy storage, telecom and industrial markets. From custom rigid copper and aluminum busbars to flexible braided jumpers and high-performance laminated busbars, our engineering and manufacturing capabilities deliver reliable, application-specific power-delivery components.
Product Categories
Rigid Busbars
Provide an effective and efficient means of delivering high power. Available in copper and aluminum, in sheet, bar and rod form options.
Features
- Swaging of rod
- Edge bend and complex forming
- Tin, Nickel, and Silver plating
- Powder coat insulation
- Brazing and welding
Flexible Busbars
Feature braided cables that provide flexibility. Available in rounded rope braids that offer 360-degree movement. Often used in industrial applications as fuses, grounding and EMI elimination (EMC). Compressed terminal versions provide ruggedness to withstand vibration.
Features
- Round and flat braid versions
- Insulated and uninsulated versions
- Stacked braid versions
- Flex/rigid combined solutions
Laminated Busbars
Offer multiple layers of conductors adhered together by heat-activated insulation. Easily implemented into the customer's product to provide alternating layers of conductor and insulation, with various insulation materials available.
Features
- Improved heat dissipation
- Low characteristic impedance
- Powder coat solutions
- Tin, Nickel and Silver plating
Flexible Grounding Jumpers
- Custom lengths
- Flat braid
- Custom ends
- Stocking packages available through distribution
Manufacturing Capabilities
Waterjet Cutting
High-pressure water mixed with abrasive cuts hard materials into complex shapes. Ideal for low-volume and prototype jobs.
CNC Mills
Computerized program operating a rotating cylindrical cutting tool moving in multiple axes. Linkable directly with CAD models.
Turret-Style Punching
Automated metal sheet fabrication that rotates many tools to cut complex shapes up to 0.25″ thick.
Semi-Automatic Bar Stock
Cutting, forming and edge-bending of bar stock. Saves material by avoiding nesting on a full sheet.
Stamping & Forming
Coil and strip processing in custom die sets for high-speed production with extreme accuracy.
Lamination
Heat and pressure insulate busbars in adhesive-lined dielectric, improving thermal and electrical performance.
Hi-Pot Testing
Nondestructive test verifying busbar insulation adequacy. Standard test voltage is 2× operating voltage + 1000 V.
Brazing
Metal items joined by melting filler metal into the joint. Suited to higher-temperature applications than soldering.
Value-Add Services
PEM Insertion & Assembly
Press-fit insertion of self-clinching threaded and unthreaded studs and nuts.
Solder Dip
Components dipped in a molten solder bath, bonding upon cooling.
Heat Shrink
Heat-applied tubing that shrinks to secure electrical insulation to a conductor.
Wire Braid Assembly
Flexible power-distribution component that eliminates vibration-related failures.
Kitting
Bundled assemblies, hardware and accessories prepared and packaged together for streamlined production.