Custom Automotive Busbar For Efficient Power Distribution
Products Description
What is the Custom Automotive Busbar for Efficient Power Distribution? It is a customized connection element designed specifically for the power distribution systems of new energy vehicles. It uses a PET insulating film to cover copper conductors for highly reliable current transmission and voltage isolation within battery packs, the DC side of inverters, and capacitor banks.
Why PET Insulation in EV Power Distribution? In the 400V to 800V high-voltage platforms of electric vehicles, the electrical insulation, temperature resistance (-40°C to +125°C), and mechanical protection properties provided by PET insulation film make it the preferred insulation solution for capacitor busbars, ensuring safe operation of the system under high current density.
Product Advantages
Low Stray Inductance Enhances Power Device Safety: The tightly laminated structure of PET insulating paper and conductive layers reduces stray inductance in the converter circuit to the nanohenry level, significantly suppressing IGBT turn-off overvoltage and reducing the risk of power device breakdown. The low inductance characteristics of the EV Laminated Busbars are particularly important for next-generation inverters using wide-bandgap semiconductors such as silicon carbide.
Customized Design for Compact Spaces: The shape, mounting holes, and terminal types are tailored to the internal layout of the motor controller, perfectly adapting to the diverse needs of different power levels and installation spaces. In space-constrained areas such as the underside of the vehicle body, the Busbar for DC-Link Capacitor can be flexibly bent to adapt to special installation environments.
PET Insulation Ensures High-Voltage Safety: PET insulating paper has excellent dielectric strength and a stable dielectric constant, providing reliable interlayer insulation within the DC bus voltage range of 300V-1500V, while maintaining good flexibility and processing adaptability for Capacitor Busbar.
Excellent Heat Dissipation Performance: The good thermal conductivity of the copper layer, combined with the flat structure, allows for rapid heat conduction from power devices to the cooling system. Although PET insulating paper is a poor conductor of heat, by optimizing the insulation layer thickness and the design of the laminated structure, the requirements for insulation and heat dissipation can be effectively balanced.
Manufacturing Advantages
| Precision Blanking and Burr Control | Using carbide progressive dies or laser cutting, the burr height at the copper layer edge is controlled within 0.03mm to prevent burrs from piercing the PET insulation layer and causing partial discharge. The first and last EV Capacitor Connector Bar of each batch undergo microscopic burr inspection. |
| PET Film Pretreatment | The film undergoes plasma activation treatment before cutting to improve wettability with epoxy adhesives, ensuring a peel strength ≥8N/cm (ASTM D903) after hot pressing. |
| Closed-Loop Hot Press Curing Parameters | A servo hot press is used, with temperature control accuracy ±2℃ and pressure distribution uniformity ±5%. Vacuum bags are used to assist in degassing, eliminating interlayer bubbles-a primary cause of insulation degradation in automotive-grade EV Laminated Busbars after humid heat cycling. |
| Three-Dimensional Bending Springback Prevention | For Z/L/U-shaped bends, an in-mold pressure-holding and cooling shaping process is used for Busbar for DC-Link Capacitor, controlling the springback angle within ±0.5° to ensure the alignment accuracy of mounting holes and capacitor/module terminals. |
Insulation Material Characteristics
PET is the preferred insulation material for EV Capacitor Connector Bar:
- Heat Resistance Grade: Class A (105°C) to Class B (130°C)
- Breakdown Strength: ≥15 kV/mm
- Thickness Specifications: 0.1mm, 0.15mm, 0.2mm, 0.25mm, 0.3mm
- Water Absorption: <0.5%
- Tensile Strength: ≥90 MPa
The advantages of PET material for Capacitor Busbar are:
- High voltage resistance and stable insulation performance
- Resistant to chemical corrosion, suitable for automotive environments
- Good flexibility, easy to bend and install
- Moderate cost, suitable for large-scale applications
contact us
If you require an EV Capacitor Connector Bar, please provide drawings and technical specifications. Our engineering team will quickly assess and propose a customized solution to help your project achieve higher efficiency and reliability.
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