EV BusBar
Products Description
EV BusBar PET insulated film capacitor busbars are electrical connection components that integrate conductive busbars and insulation layers into a single design. Through a precision lamination structure of multiple layers of copper (or aluminum) conductors and polyester (PET) film, they achieve:
High current carrying capacity: Supporting continuous currents up to hundreds of amperes, meeting the stringent power density requirements of electric vehicles and energy storage systems.
Excellent electrical insulation performance: The PET insulation layer possesses excellent dielectric strength and voltage withstand characteristics, effectively preventing arcing and breakdown risks.
Compact and modular design: Compared to traditional cable wiring, the Film Capacitor Busbar for HEV / EV Motor Control Unit connection structure is more compact, has better heat dissipation, and is simpler to assemble.
Low inductance design: Through a rational stacking and arrangement structure, parasitic inductance is reduced, improving the system's high-frequency response performance.
Material Advantages: A Perfect Combination of High Conductivity and High Insulation
1. Conductive Layer Materials
High-purity copper (T2 / C1100): Excellent conductivity, ensuring low-power transmission and high-efficiency output; surface can be treated with tin plating, nickel plating, silver plating, etc., for anti-oxidation.
High-performance aluminum (1060 / 6061): Ideal for lightweight design requirements, balancing conductivity and structural strength.
2. Insulation Layer Materials
PET insulating film (polyethylene terephthalate): High voltage withstand capability, breakdown voltage up to several kilovolts;
Excellent mechanical strength and tear resistance;
Outstanding thermal stability (long-term operating temperature up to 125°C);
Excellent dimensional stability and moisture resistance.
3. Material Bonding Technology
Utilizing a hot-pressing composite lamination process, the conductive layer and PET insulating layer are firmly bonded together, forming a stable multi-layer composite structure with excellent mechanical strength, bending resistance, and insulation reliability.
Manufacturing Advantages: Full-Chain Capabilities from Precision Machining to System Matching
Precision CNC Machining and Laser Cutting
Utilizing advanced CNC machining equipment, high-precision cutting and drilling of the conductor layer are achieved, ensuring dimensional tolerances are controlled within ±0.05mm. Laser cutting technology is employed to avoid thermal deformation, guaranteeing Copper Busbar for DC link EV Film Capacitor contour accuracy and edge smoothness.
Automated Lamination and Film Application Process
The PET insulation layer is laminated using fully automated equipment, resulting in a smooth, bubble-free finish. High-temperature lamination and curing ensure adhesion strength and insulation integrity.
Rigorous Electrical and Insulation Testing
Each Copper Busbar for Electric Vehicle Capacitors undergoes insulation resistance testing, dielectric withstand voltage testing, and continuity testing before leaving the factory, ensuring the product meets the high safety standards of the new energy industry.
Customization and Modularization Capabilities
Copper Busbar for Hybrid Electric Vehicles Film Capacitor shape, number of layers, and insulation methods are customized according to customer circuit drawings and installation space, supporting rapid prototyping and mass production to meet OEM/ODM project requirements.
Product Advantages: Balancing Performance, Safety, and Reliability
| Core Advantages | Explanation |
| High Current Carrying Capacity | High-purity Film Capacitor Copper Busbar for Electric Vehicles offers high current transmission efficiency and extremely low resistance, effectively reducing energy loss. |
| Excellent Insulation and Protection | The PET insulation layer boasts strong breakdown resistance and excellent temperature resistance, ensuring safety and reliability. |
| Compact Structure and Easy Installation | Modular Copper Busbar for DC Link Power Electronics Capacitors reduces wiring complexity and improves system assembly efficiency. |
| Strong Corrosion Resistance and Environmental Resistance | The surface electroplating layer and PET coating effectively prevent oxidation, moisture, and salt spray corrosion. |
| High Consistency and Traceability | Comprehensive quality control throughout the entire process ensures consistent performance between batches. |
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