Bus bars can be classified into two basic categories, single layer and multi-layer. A single layer bus bar consists of only a single conductor layer that is either insulated or un-insulated. Multi-layer bus bars contain two or more conductors that are separated by insulating layers. A subcategory for both types of bus bars is that of added value. Basically, the bus bar will contain additional components such as fuses, breakers, cable extensions, support brackets and other devices as required by the application.

After making a decision to use a single layer or multi-layer bus bar, one must consider and choose from a variety of different insulation configurations and sealing methods. There are many construction options to choose from for both the insulation and sealing methods, and they somewhat depend on whether a single layer or multi-layer bus bar has been chosen.

• Flexible Dielectric Film
• Rigid Epoxy Glass Board
• Powder Coating

• Fexible Dielectric Film
• Rigid Epoxy Glass Board

• Potting - filling the exposed area where the outer insulation extends beyond the conductors with an epoxy material. This option can be applied to then as well as thick bus bars and is an excellent option when maximum protection from the environment is require.
• Pinch Off - the outer insulation is designed to overlap the conductor(s) by a specific distance. It is pinched and sealed together during the lamination process. This method is not recommended for bus bars in excess of 0.186" thick or in highly moist environments.
• Cavitation - a rgid epoxy glass insulation material with machined pockets for the conductors are used as inner and outer insulation layers which completely encapsulate the inner conductors when laminated together with an adhesive. This option is also employed in extreme environments.
• Powder Coating - all outer surfaces are completely coated with an epoxy that is cured to form a protective insulation. This option is well suited for extreme environments.