Home / All / Silicone Overmolding Products / Automotive Silicone Overmolding / Custom LSR Overmolded Copper Busbar Insulation Components
Custom LSR Overmolded Copper Busbar Insulation Components
| Share | |
|---|---|
| Categories | Automotive Silicone Overmolding |
| Brand | SiliconePlus | Silicone OverMolding Manufacturing |
| Product Type | LSR Overmolded Copper Busbar Component |
| Silicone Material | Liquid Silicone Rubber / LSR |
| Metal Substrate | Copper / Copper Alloy / Customer-Specified Metal |
| Molding Process | LSR Insert Molding / Silicone Overmolding |
| Main Function | Electrical Insulation / Edge Protection / Sealing / Positioning |
| Silicone Coverage | Partial Coverage / Local Encapsulation / Custom Area |
| Exposed Area | Terminals / Contact Surfaces / Mounting Holes |
| Silicone Hardness | Customized According to Application |
| Color | Orange / Black / Custom Color |
| Custom Input | 2D Drawing / 3D File / Physical Sample |
| Service | OEM/ODM Custom Manufacturing |
| MOQ | 500 pcs |
| Download |  |
Detail Information
SiliconePlus manufactures custom LSR overmolded copper busbar components for EV battery systems, high-voltage electrical modules and industrial power assemblies.
Liquid silicone rubber is molded onto selected sections of a copper or metal conductor. Electrical contact surfaces, mounting holes, welding areas and terminal zones can remain exposed while the silicone forms a controlled insulation and protection layer.
This is a drawing-based custom manufacturing service. The busbar geometry, metal surface, silicone coverage, exposed contact areas, assembly method and electrical requirements must be reviewed before tooling.
Insulate the Required Area Without Covering Electrical Contacts
Copper busbars often contain several functional areas within one component. Some sections carry current or connect to terminals, while other sections may need insulation, edge protection or separation from nearby conductive parts.
LSR insert molding can apply silicone only to the defined protection area. The mold keeps contact surfaces, bolt holes, welded sections and alignment features free from silicone.
Compared with manually installing separate sleeves or protective pads, an integrated overmolded structure can reduce loose components and keep the insulation area aligned with the metal conductor.
Critical Busbar Overmolding Design Points
Contact Area Protection
Terminal surfaces, welded zones and electrical contact areas must remain clean, exposed and dimensionally controlled after molding.
Metal Insert Positioning
The tooling must hold the busbar securely to control height, flatness and silicone coverage during LSR injection.
Coverage Boundary
Mold shut-off areas define where the silicone begins and ends while limiting flash around holes, edges and narrow metal features.
Retention Structure
Holes, slots, steps or local undercuts may be evaluated to improve mechanical retention between the silicone and metal substrate.
Product Parameters
Item | Specification |
Product Type | LSR Overmolded Copper Busbar Component |
Silicone Material | Liquid Silicone Rubber / LSR |
Metal Substrate | Copper / Copper Alloy / Customer-Specified Metal |
Process | LSR Insert Molding / Silicone Overmolding |
Main Function | Electrical Insulation / Edge Protection / Sealing |
Silicone Coverage | Partial Coverage / Local Encapsulation / Custom Area |
Exposed Area | Terminals / Contact Surfaces / Mounting Holes |
Silicone Hardness | Customized According to Application |
Color | Orange / Black / Custom Color |
Custom Input | 2D Drawing / 3D File / Physical Sample |
Service | OEM/ODM Custom Manufacturing |
MOQ | 500 pcs |
Custom Silicone Coverage for Different Busbar Structures
Silicone coverage can be designed according to the busbar shape and final electrical assembly.
Common options include local edge encapsulation, insulation around bends, flexible separation areas, protected mounting sections and molded barriers between adjacent conductive zones.
Before tooling, our engineers review copper thickness, flatness, dimensional variation, surface coating, insert locating points, silicone flow direction, gate position, venting and demolding requirements.
Typical Application Projects
EV Battery Modules
Used for custom copper conductors and busbar sections requiring local insulation or protected installation areas inside battery modules.
Battery Management Systems
Suitable for conductive interfaces and metal connection parts that require controlled separation from nearby electronic components.
High-Voltage Junction Units
Applied to custom metal conductors, terminal sections and internal connection structures used in high-voltage electrical assemblies.
Industrial Power Equipment
Used for custom conductive bars and metal electrical components requiring localized silicone insulation or edge protection.
DFM Information Required Before Tooling
Please provide the copper busbar drawing, 3D file or physical sample together with the required silicone coverage area.
The drawing should clearly identify electrical contact surfaces, mounting holes, welding zones, critical dimensions and areas that must remain free from silicone.
We also need the metal material, surface treatment, silicone requirements, assembly method, operating environment, inspection standard and estimated production quantity.
FAQ About LSR Overmolded Copper Busbars
Can silicone cover only part of the copper busbar?
Yes. The mold can expose terminals, bolt holes, contact surfaces and welded sections while applying silicone only to the required protection area.
Can different busbar shapes be overmolded?
Flat, bent, stepped and custom-shaped metal conductors can be evaluated. Feasibility depends on insert rigidity, locating surfaces, dimensional tolerance and silicone coverage.
How is silicone retained on the metal?
The design may use mechanical locking features, material bonding or a combination of both. The most suitable solution depends on the metal surface and product structure.
Can coated or plated copper inserts be used?
The coating or plating must be reviewed because it may affect bonding, mold handling and the areas that must remain electrically functional.
What information is required for quotation?
Please send the 2D drawing, 3D file or physical sample, metal specification, silicone coverage, exposed contact areas, target quantity and application requirements.
Contact SiliconePlus for DFM review, custom tooling, sampling and OEM production of your copper busbar silicone overmolding project.
Related Products
Review
- Loading...
Please send your message to us
- *Phone
- *Title
- *Content
Silicone Empowers Excellence
Contact Person
