Wellele

    • 800V Busbar Insulation

    Busbar insulation for 800V EV architectures and high-voltage switchgear: heavy-wall heat shrink tubing, fiberglass and PTFE sleeving, sized to your busbar drawing and made in our own factories.

    800V busbar insulation with heat shrink tubing on copper busbars

    What we supply

    Wellele is the export brand for this range. Manufacturing is coordinated through operations in Suzhou and Anji, China; the manufacturing location and documentation scope for a specific part are confirmed with the quotation. Inspection records, test reports and compliance documents are supplied according to the product and the documentation scope agreed on the order.

    Key reference data

    Voltage class

    800V DC busbars; busbar tubing rated 8.7/15kV and 26–35kV

    Shrink ratios

    2:1, 3:1, 4:1 · dual-wall adhesive available

    PTFE sleeving

    Heat-shrink grade rated 260 °C

    Flame retardancy

    Flame-retardant grades; UL94 / VW-1 test report supplied with the order

    UL certification

    Available on specified products : confirm model coverage with our engineers

    Documentation

    Dielectric, flammability and dimension reports with every shipment

    Selection is confirmed against your drawing: busbar cross-section, peak voltage, creepage and operating temperature. If you need a value on paper before ordering, ask: the datasheets are ours to send.

    Why 800V changes the specification

    The jump from 400V to 800V battery architectures raises voltage stress on busbar insulation. Three things change:

    Voltage standoff

    Thicker wall or higher-rated material for the same air gap, or increased creepage distance.

    Partial discharge

    Sharp edges, thin coating and poor adhesion fail at higher DC voltage. Heavy-wall heat shrink and coated sleeving manage edge coverage better.

    Thermal duty

    Higher current density means higher continuous temperature. Fiberglass, silicone and PTFE hold rating where standard polyolefin does not.

    Send the busbar cross-section, voltage and clearance requirement. We match the insulation option and size before quotation.

    What we supply for 800V busbars

    Heavy-wall busbar heat shrink

    Cross-linked polyolefin · 8.7/15kV and 26–35kV ratings

    Straight busbar runs, joints and terminations. 2:1, 3:1 and 4:1 shrink, dual-wall adhesive for sealing.

    Fiberglass & silicone sleeving

    Silicone-coated fiberglass · inner-fiber outer-coat

    Tight bends, harnesses and high-temperature zones where heat shrink does not fit.

    PTFE & fluoropolymer tubing

    PTFE / FEP / PFA · 260 °C heat-shrink grade

    Chemical and temperature extremes, plus polyimide (PI) tubing for the highest duty.

    Recommended products

    8.7/15kV Busbar Heat Shrink Tubing

    Cross-linked polyolefin · Heavy & medium wall

    26–35kV Busbar Heat Shrink Tubing

    Cross-linked polyolefin · Highest busbar rating

    4:1 Dual-Wall Adhesive Heat Shrink Tubing

    Polyolefin · Adhesive-lined, sealing

    Silicone-Coated Fiberglass Sleeving

    Inner fiber, outer silicone coat

    PTFE Heat Shrink Tubing (260 °C)

    Fluoropolymer · High temperature

    Silicone Self-Adhesive Tape

    Self-fusing · Joints & terminations

    Heat shrink, fiberglass or PTFE — which one?

    Heat shrink tubing

    Straight runs, joints, terminations · 2:1–4:1

    Fiberglass & silicone sleeving

    Tight bends, harnesses, high temperature

    PTFE / PI tubing

    Chemical and temperature extremes

    Most 800V busbar drawings use a combination: heavy-wall heat shrink for the straight runs, coated sleeving where the busbar bends or meets the harness, PTFE where temperature or chemicals bite. Send the drawing and we put the combination together.

    Frequently asked questions

    Can busbar heat shrink tubing handle 800V?

    Yes. Our busbar tubing is rated 8.7/15kV and 26–35kV, so an 800V DC busbar sits well inside the rating. Wall and overlap are still confirmed against your peak voltage and creepage drawing before quotation.

    Do you supply test reports with the order?

    Inspection records, test reports and compliance documents are supplied according to the product and the documentation scope agreed on the order. Datasheets are available before ordering.

    Are the products UL certified?

    A UL-certified range is available on specified products. Confirm the exact model coverage with our engineers before ordering, and we send the certificate with the documentation.

    Where are the products made?

    Manufacturing is coordinated through operations in Suzhou and Anji, China; Wellele is the export brand. The manufacturing location for a specific part is confirmed with the quotation.

    Heat shrink or fiberglass — which is better for an EV busbar?

    For straight runs, heavy-wall heat shrink. For tight bends, harnesses and high-temperature zones, fiberglass or silicone-coated sleeving. Most EV busbars use both.

    What information do you need for a busbar insulation quote?

    Busbar width x thickness, voltage and peak voltage, operating temperature, clearance or creepage requirement, annual quantity and any required test standard.

    Application deep-dives

    Focused pages inside this route, with the published ratings and the inputs we need to quote.

    EV High-Voltage Protection

    Abrasion, heat and colour on pack and HV harness runs, with component ratings kept separate from system approval.

    Need a custom size or spec?

    Send busbar cross-section, voltage, temperature and clearance: we return a sized recommendation, lead time and the test report list.

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