EV Capacitor Connector Bar
Products Description
In the electric drive assemblies of new energy vehicles, the busbar connection area is often exposed to a complex environment of alternating high frequency, high voltage, high temperature, and vibration. Traditional insulation solutions are prone to ageing, warping, breakdown, or assembly deviations. EV Capacitor Connector Bar PET insulation paper, through high-precision processing and a stable material system, provides customers with a higher level of insulation protection solutions.
Its core functions include:
Insulation isolation between busbar conductors
Short-circuit protection in capacitor terminal connection areas
Improving the operational safety level of high-voltage systems
Reducing frictional damage during assembly
Optimising busbar structural stability and installation consistency
Meeting the lightweight and miniaturisation requirements of new energy systems
Detailed Specifications
Precision Interface Matching
The terminal area is machined for high flatness, ensuring tight contact with capacitor terminals or power modules; EV Film Capacitor Busbar supports multiple fixing methods for convenient and reliable installation.
01
PET Insulation Paper Treatment
The insulation layer edges are specially rounded and reinforced to prevent electric field concentration and mechanical damage, thereby improving the long-term voltage withstand capability.
02
Surface and Marking
Optional laser engraving of batch and specification information, supporting QR code traceability; the surface is flat and uniform, facilitating subsequent assembly and quality inspection.
03
Local Flexibility Design
Key bending areas retain sufficient flexibility to absorb thermal expansion and contraction, as well as vibration stress, thereby preventing fatigue cracking during long-term use for EV Capacitor Connector Bar.
04
Packaging Protection
Professional anti-static, moisture-proof, and impact-resistant packaging ensures that the product's performance is not affected during transportation and storage.
05
Technical Features: Strict Control of "Edge Effect" and Partial Discharge
| Ultimate Edge Coverage and Electric Field Homogenization | The electric field is most concentrated at the cut edges of the Busbar for DC-Link Capacitor. We employ advanced edge folding and wrapping or secondary glue injection sealing technology, using PET material to completely wrap the sharp metal cut surface internally, eliminating the air-metal interface, significantly reducing the edge electric field intensity, and effectively suppressing corona discharge and partial discharge (PD) under high voltage conditions. |
| Bubble-Free Interlayer Bonding Technology | Any tiny air gap between the insulating layer and the EV Laminated Busbars can become a breeding ground for gas ionisation under high voltage. Through a specific process, the PET insulating paper achieves 100% air gap-free bonding with the copper surface, eliminating the hidden danger of internal discharge. |
| High-frequency pulse withstand capability | Faced with the extremely high voltage change rate of SiC (silicon carbide) devices, the low dielectric constant of PET material effectively reduces the charging and discharging losses of the Film Capacitor Copper Busbar for Electric Vehicles' distributed capacitance, avoiding thermal runaway caused by the high-frequency dielectric heating of the insulation layer. |
Application Advantages: Empowering Next-Generation Electronic Control Platforms
Increased System Power Density
With the widespread adoption of 800V high-voltage platforms, capacitor busbars require thinner and stronger designs. Our PET insulation solution significantly reduces volume while maintaining creepage distances, enabling lighter designs for electronic control systems.
Reduced Assembly Time
Copper Busbar for DC Link Film Capacitor for Electric Car design replaces cumbersome manual wiring, supporting automated robotic assembly lines and significantly improving the production efficiency of electrolytic/film capacitor modules.
Enhanced Environmental Reliability
The automotive battery terminal bus bar has passed stringent tests in extreme cold, heat, high humidity, and salt spray, meeting automotive-grade requirements throughout its entire lifecycle.
contact us
If you are looking for a supplier of EV Capacitor Connector Bar PET insulation paper that combines insulation reliability, structural compatibility, and a stable delivery system, please submit your drawings or project requirements. Our engineering team will provide you with a more efficient and mass-producible solution.
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