Busbar For Busbar Film Capacitor
Busbar for Busbar Film Capacitor are key conductive and connecting components in the power electronic systems of new energy vehicles. They are mainly used for low-impedance connections of thin-film capacitors in DC buses, motor controllers (MCUs), inverters, and battery systems.
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Product Introduction
Busbar for Busbar Film Capacitor (New Energy Vehicle Film Capacitor Busbar) is a core conductive connection component specifically designed for film capacitors in new energy vehicles. Focusing on the requirements of high current, low loss, and high reliability transmission, it connects film capacitors to key equipment such as motor controllers, undertaking power distribution and signal transmission functions. Based on highly conductive materials, combined with a composite insulation structure and precision manufacturing, the product is adapted to the compact, lightweight, and long-life requirements of new energy vehicles. Its core characteristics, such as technical adaptability and reliability, directly affect the safety and efficiency of the entire vehicle's electrical system. It is a preferred choice for engineering procurement that balances performance, cost, and compliance, adhering to the IATF 16949 standard and meeting the selection needs of engineering procurement and system engineers.
performance advantages
High-efficiency, low-consumption conductivity
The BusBars uses high-purity copper/aluminum material, which has been precisely processed and optimized. The resistance per unit length is 0.001-0.01Ω, and the power loss is more than 10% lower than similar products. It can stably carry high current, adapt to the high power requirements of the whole vehicle, improve energy utilization efficiency, and reduce heat generation.
High-reliability safe insulation protection
The Busbar Connector uses polyimide film insulation, which is integrally molded without seams. The breakdown strength is ≥25kV/mm, and the withstand voltage is 500-1500V. It can withstand overload, prevent leakage and insulation failure, ensure the safety of equipment and personnel, and is compatible with the high-voltage system of the whole vehicle.
Strong adaptability to operating conditions
The Automotive BusBar is temperature resistant from -40℃ to 125℃, and is vibration-resistant and corrosion-resistant. The service life under normal operating conditions exceeds 10 years, and maintenance-free for 8 years, reducing the maintenance cost of the whole vehicle and ensuring long-term reliable operation under complex conditions.
Customization process
Drawing Submission and Requirements Assessment: The customer provides drawings outlining their customization requirements, including Battery BusBar dimensions, conductive layer, and insulating layer. Our company, considering product processes, material characteristics, and new energy vehicle engineering standards, assesses the feasibility and delivery time/cost of the proposed solution, providing optimization suggestions to ensure the product is suitable for the customer's operating conditions.
Sample Order Confirmation: After price confirmation, the customer places a sample order and prepays 50% of the mold fee. Our company, utilizing its own mold workshop, initiates custom mold production, ensuring the mold precision meets Power BusBar size requirements (tolerance ≤ ±0.1mm).
Sample Production and Testing: After mold completion, our company produces 1-20 samples free of charge according to the BusBar Systems's core processes, sending them to the customer for testing and providing a test report to verify product dimensions, electrical performance, and compatibility with film capacitors.
Bulk Order Placement and Production: After sample testing, the customer pays the remaining mold fee, places a bulk order, and prepays 30% of the payment. Our company produces in bulk according to IATF16949 standards, strictly controlling core Automotive Busbar parameters, with delivery time controlled within 15-20 days.
Payment and delivery: After the products are mass-produced, they will be 100% tested and a report will be issued. After the customer pays the balance, the products will be delivered in engineering-grade packaging according to the product size. Samples of each batch of IGBT BusBar will be retained and sealed for five years for easy traceability.
Usage Notes
Correct Selection
Strictly adhere to the vehicle's electrical parameters and film capacitor specifications to select compatible Busbar Insulations. Ensure that the product's resistance, withstand voltage, current carrying capacity, and other parameters meet requirements to avoid malfunctions caused by improper selection. Consult our professional technical team for selection advice.
Installation Standards
Operate according to the BusBars installation instructions and vehicle assembly standards. Ensure the product is securely connected to relevant components and that interfaces are clean to avoid mechanical damage (especially to the product's insulation layer). Strictly control the temperature during welding to prevent damage to the product's insulation and conductive layers.
Regular Inspection and Maintenance
Regularly inspect the busbar for Busbar Film Capacitor's appearance, checking the conductive layer, insulation layer, and connections for any abnormalities. Repair or replace faulty products promptly. Regularly test the product's electrical performance, focusing on welded joints to prevent incomplete soldering or detachment.
Thermal Management Measures
The Battery BusBar generates heat when transmitting current. Under high-load conditions, it is necessary to coordinate with the vehicle's thermal management system and implement effective heat dissipation measures to control the product's operating temperature within the range of -40℃ to 125℃ to prevent overheating damage.
Frequently Asked Questions
Q: WHAT ARE YOUR CERTIFICATES?
A: We have ISO9001, IATF 16949 certificates, RoHS and Reach.
Q: DO YOU TEST ALL YOUR GOODS BEFORE DELIVERY?
A: Yes, we have 100% test before delivery for busbar.
Q: WHAT'S YOUR DELIVERY TIME?
A: About 10-15 days for busbar samples, 10-15 days for mass production.
Q: CANY YOU PRODUCE ACCORDING TO THE SAMPLES?
A: Yes, we can produce by your busbars samples or technical drawings. We can build the molds and fixture.
Q: WHY CHOOSE OUR Busbar for Busbar Film Capacitor?
A: We are the original factory in China, can supply the Ex-works;
We have been in professional in new energy field 15 years more and have enough successfull experiences to help you improve technology but cost down;
We have branches sales office in India, Iran, Spain, Germany, Japan, can supply the fast local service.
contact us
If you have any questions about the procurement, selection, customization, and sample application of busbar for Busbar Film Capacitor, please feel free to contact us. Our professional team will provide technical adaptation, cost reduction suggestions, and sample support, leveraging our company's advantages to help your project be successfully implemented.
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