Aluminium bus bars

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Back in the 1970s, busbars were flat strips of copper that panel builders bought and installed in low voltage (LV) switchboards. In the 1980s, mounting holes appeared and busbars were current-rated. However, aligning these holes could be time-consuming during installation. By the 1990s, busbars with extruded profiles became popular due to their lighter weight and easier mounting process.

The 2000s introduced aluminium into the mix, with major manufacturers creating vertical profiled bus bars with varying current ratings such as 630A, 800A, 1000A, and more. Fast forward to today, we have aluminium horizontal profile busbars that connect vertically, offering a broader range of current ratings.

The evolution of the humble busbar over the last 50 years is noteworthy. In the past decade, busbars have largely replaced hard-wired power distribution in industrial settings. One key factor in this transformation is the increasing use of aluminium, which boasts a lower cost in today’s highly competitive markets. Recyclable aluminium is less susceptible to scarcity and commodity market fluctuations, resulting in cost savings of up to 35%.

For more information, please visit Aluminium Bus Bar.

Aluminium is up to 70% lighter than copper and offers a soft, pliable nature, which allows it to be easily formed into various customised profiles through processes similar to pasta extrusion. A single operator can quickly and easily install aluminium busbars thanks to their lightweight. Their customised profiles ensure they slide or dovetail securely into position.

Hollow and extruded profile busbars have a larger surface area compared to standard rectangular sections, providing superior heat exchange and more efficient thermal dissipation. This is especially advantageous in cramped enclosures. Custom extruded profiles can further enhance natural convection, improving the mix and flow of heat and air. Today’s aluminium busbars demonstrate excellent thermal management, handling temperature rises of 60°C above ambient temperatures without issue. Featuring hollows, protrusions, and ionised surfaces, they optimise heat dissipation and reduce resistivity.

For more information, please visit Industrial Roll of Aluminum Foil.