nVent Flexibar: A Flexible Power Distribution System

For distributing energy across a wide variety of electrical equipment, busbars are the standard solution for many industries. They’re a key component of power distribution for their versatility and highly durable construction, but their heavy and rigid copper design has its limitations. 

Sometimes connections have tight spaces that need to be accommodated, or require intricately-arranged busbars, but arranging them in complex ways can quickly become heavy, cumbersome, and inefficient. When a project demands a more practical, flexible approach, nVent’s Flexibar is the ideal solution. 

What is Flexibar?

Flexibar is a unique power distribution medium that serves the same purpose as a traditional busbar, while introducing numerous benefits, expanding their usefulness and practicality in a variety of ways. Their main advantage is in the name: a flexible design featuring layers of thin copper housed in a PVC plastic sleeve that allows it to be bent and twisted into nearly any configuration with ease. 

This allows Flexibar to accommodate cramped and crowded spaces without sacrificing durability. The bending radius of Flexibars are sharp and small, allowing them to fit precise angles, saving valuable space. This also allows them to be adjusted easily, an impossibility for busbars. 

The Advantages of Flexibar

While flexibility is their main advantage over busbars, Flexibars offer a broad scope of benefits that make connecting power sources and other electrical equipment easier. It all starts with their unique, layered design, which isn’t just useful for bending.

Space-saving, Lightweight Design:

Although very durable, the solid copper design of busbars makes them heavy, especially when a connection requires more than a few of them running from one component to the next. Flexibars are much lighter thanks to their layered design, with thin layers of copper stacked on top of each other, housed in a soft plastic. 

Flexibars also offer numerous ways to save space when connecting components; since they can be bent and contorted in almost any way, Flexibars can always be arranged in the most space-conscious configuration possible. 

Ease of Operation:

Flexibars can also be used in place of copper wiring, offering a more durable solution that allows for better cable management. Copper wires often require a ring terminal on each end, but Flexibars allow the user to just drill the bolt-hole right into the connection point. 

If a Flexibar is too long, it can even be cut to size, allowing it to be adjusted to fit the constraints of any connection, no matter how specific. 

Oftentimes, traditional busbars need to be sprayed with an epoxy for insulation in short clearance distances. Flexibar’s PVC outer layer already acts as insulation, eliminating the need for spraying.

Reduced Installation Time:

One major limitation of busbars is how time-consuming they can be to correctly install. Busbar components are attached with lugs that can take time to screw in place. Busbars are also rigid and must be engineered specifically for the application they’re being used for. 

If the configuration of a busbar doesn’t meet the needs of a connection, it needs to be replaced, and this could mean ordering a new one, or even engineering a new one specifically for a connection. 

Flexibars mitigate both of these time-consuming factors. They only require bolting on each end, and do not need to be engineered specifically for a certain application. Flexibars can be bent and re-bent with ease, meaning configurations can be easily adjusted instead of needing to wait for a new busbar to be ordered or designed. 

Compared to large cables, Flexibars can also be bent easier, making them faster to install. 

Improved Aesthetics:

Flexibars have a uniform, sleek design that seamlessly accommodates the appearance of any electrical system without making it look busy or disorganized. Part of this is due to their black housing, but this is mostly because of their flexibility. 

While a connection that uses lots of busbars can easily look encumbered, and lots of cables can look messy, Flexibar fixes both of these aesthetic woes. Because they can be bent into nearly any configuration, Flexibars can always be positioned neatly. This allows for a more efficient use of space while looking better than traditional power delivery solutions.

Flexibar Applications

As a replacement for both busbars and traditional copper wiring, Flexibar can be used in a wide variety of applications for many different industries. Here are just some of the ways Flexibar can be used to deliver power for transportation, power generation, machinery and more:

• Low-Voltage Power Distribution
• Motor Control Centers
• Switchboards
• Drive Systems
• Power Transformers
• Electrical Machinery and Vehicles
• Power Supplies

Dynamic Electronics: Procuring the Best Manufacturing Solutions

For any manufacturing need in almost any industry, Dynamic Electronics can procure and engineer the best solutions possible. When you choose Dynamic Electronics as your manufacturing partner, you’ll be backed by 30 years of experience serving OEMs and end-users. Contact us today to learn more about how we can help you with your manufacturing needs.