High-purity copper rods, typically C10100 or DHP copper, are commonly used for small busbars due to their excellent electrical conductivity and mechanical properties.

Recommended Copper Types

For small busbars, the most suitable copper rods are:

• C10100 Copper (Electrolytic Tough Pitch, ETP): Contains a minimum of 99.90% copper and offers very high electrical conductivity (around 101% IACS), making it ideal for efficient current conduction in small busbars . It is also suitable for applications where oxygen-free copper is required, such as in sensitive electronic connections or welding .
• DHP Copper (Deoxidized with Phosphorus): While slightly lower in conductivity (approximately 85% IACS), DHP copper is easier to braze or weld and resists softening at elevated temperatures, which is useful in busbars that may experience thermal stress .

Physical Form and Temper

• Rod Shape: Small busbars often use solid round copper rods for compact installations, providing sufficient current-carrying capacity while being easy to bend or machine .
• Temper: Soft or annealed copper rods are preferred for small busbars that require bending or forming, while harder tempers are used when mechanical rigidity is important .

Key Considerations

• Electrical Conductivity: High conductivity ensures minimal voltage drop and efficient power distribution.
• Mechanical Strength: Copper rods must withstand clamping forces and thermal expansion without deformation.
• Surface Quality: Smooth, polished surfaces improve contact reliability and reduce oxidation issues.
• Size Selection: The rod diameter should match the current rating of the busbar, considering both thermal and electrical limits . In summary, C10100 or DHP copper rods in soft or standard temper are typically used for small busbars, balancing high conductivity, mechanical flexibility, and ease of fabrication for reliable electrical performance .