EV Laminated Busbars
Products Description
EV Laminated Busbars have become a key electrical connection component in high-voltage DC transmission for new energy electric vehicles and energy storage systems. Their composite laminated structure of multiple layers of conductive copper foil and insulating film achieves low inductance, low impedance, and highly reliable current transmission.
Compared to traditional rigid copper busbars, new energy film capacitor busbars offer superior electromagnetic compatibility (EMC) and heat dissipation performance, significantly reducing system noise and improving energy conversion efficiency. They are the preferred electrical connection solution for core components such as electric vehicle drive systems, DC fast-charging modules, and energy storage inverters.
Product Features and Structural Advantages
The Automotive BusBar PET Insulation utilizes high-conductivity copper or aluminum as the primary conductor layer, and a high-voltage, low-dielectric-constant insulating film as the dielectric layer. The design is formed through high-temperature lamination. The thickness, routing, and insulation distance of each layer are precisely designed based on the customer's circuit requirements, ensuring a compact structure, optimal wiring, and stable performance.
Key Structural Features:
Multi-layer Conductor Design: Effectively shortens the current path, reduces loop inductance, and improves system response speed.
Film Insulation: Utilizing high-insulation materials such as polyimide (PI) and polyester (PET), the layer withstands voltages exceeding 2.5–5kV, meeting the high-voltage requirements of EV applications.
High-Precision Lamination: Vacuum lamination and CNC positioning technology ensure uniform interlayer gaps and a secure fit.
Modular Interface Design: Flexible compatibility with power modules, capacitors, IGBTs, SiC/MOSFETs, and other devices enables integrated assembly.
EMI Suppression: Optimized Auto Bus Bar layout significantly reduces parasitic inductance and loop coupling, improving system EMC stability.
Material Advantages
High-quality materials are the foundation of automotive electrical bus bar performance. We rigorously select conductors and insulation materials that meet international standards to ensure product stability and longevity in high-voltage, high-temperature, and high-frequency environments.
1. Conductor Layer Material
T2 copper or aluminum alloy is selected for excellent conductivity and oxidation resistance.
The copper layer thickness can be customized (0.5mm–3mm), and the surface can be plated with tin, silver, or nickel to enhance weldability and corrosion resistance.
2. Insulation Layer Material
Polymer dielectric materials such as DuPont PI film, PET, and PEN are used, offering high dielectric strength and excellent heat resistance (up to H-class 180°C).
The multi-layer design effectively prevents partial discharge and breakdown, enhancing system safety.
3. Adhesive and Laminating Material
An epoxy-modified adhesive layer is used, cured through a heat-pressing process, ensuring a tight bond between the layers, free of bubbles and delamination.
This ensures stable conduction even under long-term vibration and thermal expansion and contraction.
Design Advantages
We not only provide standardized Busbar for DC-Link Capacitor products, but also focus on customized designs. Through 3D current simulation and electromagnetic compatibility analysis, we help customers achieve the optimal structural layout, balancing space utilization and thermal performance.
Custom design capabilities include:
Electrical path optimization: Design the shortest transmission path based on power module distribution and current direction to minimize losses.
Insulation thickness and material combination: Match the optimal material system based on the voltage rating and operating environment.
Thermal management solution: Integrate heat sinks or thermally conductive silicone pads into the busbar for Power Capacitor to improve system temperature balance.
Diverse interfaces and connection methods: Support bolts, welding, plug-in, and press-fit connections.
3D modeling and prototype verification: Our engineering team can complete prototype development and electrical performance verification in a short period of time.
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