EV Capacitor Busbar

 

Apollo busbars are manufactured according to electrical conductivity, thermal management, and mechanical strength requirements in EV, ESS, PV inverters, and industrial power systems.

 

For copper busbars, we commonly use C1100 pure copper and T2 electrolytic copper with high electrical conductivity. The copper material provides low-resistance current transmission and stable thermal performance under continuous high-current operation.

 

For laminated busbars, multiple copper layers are combined with PET, PI, or epoxy insulation films to shorten current paths and reduce electromagnetic interference. The optimized laminated structure helps reduce stray inductance in high-frequency switching applications such as SiC inverter systems.

 

For flexible busbar products, copper foil layers or braided copper structures provide mechanical flexibility for vibration compensation, thermal expansion absorption, and compact battery pack installation.

 

Apollo owns precision tooling capabilities including progressive stamping dies, CNC machining, and controlled bending processes to achieve stable dimensional accuracy for customized busbar production.

 

 

Parameter	Specification
Copper Material	C1100 / T2 Pure Copper
Copper Conductivity	≥100% IACS
Thickness Range	1 mm- 20 mm Custom
Surface Treatment	Tin Plating / Nickel Plating / Silver Plating
Insulation Method	PET Film / Epoxy Coating / Powder Coating
Machining Accuracy	Tolerance ±0.01mm
High Voltage Insulation	Dielectric Breakdown Voltage Testing
Application	EV Battery, ESS, UPS, PV Inverter

 

 

Busbar performance depends on reliable electrical connection and insulation protection. Apollo applies different joining technologies according to current density, mechanical load, and environmental conditions.

Copper busbars can be processed with laser welding, resistance welding, diffusion welding, and mechanical joining methods. For copper-to-aluminum applications, laser welding parameters are controlled to reduce brittle intermetallic compound formation and maintain mechanical strength.

For insulated busbars, Apollo provides PET laminated insulation, epoxy powder coating, and heat-shrink protection. Insulation materials are selected according to voltage rating, thermal conditions, and environmental requirements.

Typical insulation performance includes:
UL94 V-0 flame-retardant materials
Dielectric breakdown voltage testing
Surface insulation resistance inspection
Environmental durability verification
Surface treatments including tin plating, nickel plating, and silver plating improve oxidation resistance and contact stability, especially for high-current applications exposed to humidity and temperature cycling.

 

 

Apollo applies a complete quality management system from incoming material inspection to final shipment verification.

 

Copper material composition is checked before production. During manufacturing, dimensional inspection is performed using CMM measuring equipment, optical image measurement systems, and process monitoring methods.

 

For customized busbar projects, Apollo supports PPAP Level 3 documentation including:

Process Flow Diagram

PFMEA

Control Plan

Material Certification

CPK Process Capability Report

 

Final inspection includes:

CMM measurement accuracy up to 0.0007mm

Electrical conductivity testing

Temperature rise testing

High voltage withstand testing

Insulation resistance testing

Mechanical strength verification

Apollo production follows ISO 9001 and IATF 16949 quality management requirements to support automotive and new energy supply chains.

 

 

 

 

Send your 2D/3D CAD drawings (.STEP, .DWG) or electrical specifications to the Apollo engineering team. We provide free DFM analysis, material selection suggestions, and manufacturing evaluation within 24 hours.

 

With in-house stamping, welding, machining, and insulation capabilities, Apollo supports prototype development and stable mass production for EV, ESS, PV inverter, and industrial electrical applications.