Busbar Insulations
Busbar Insulations, as a key conductive and insulating component that connects thin film capacitors with power devices, battery packs, motor controllers, and high-voltage distribution units, are not only power transmission channels, but also engineering grade components that ensure high-voltage safety, optimize layout, reduce losses, and improve system life.
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Product Introduction
Unlike traditional exposed copper bars or simple wire harnesses, Busbar Insulations designed specifically for new energy vehicle film capacitors are composite components that integrate high conductivity transmission, electrical safety isolation, mechanical structural support, and thermal management functions. It not only needs to solve the problem of low loss in high current transmission, but also needs to address the challenges of creepage distance, electrical clearance, and temperature and humidity resistance in high voltage environments through the application of high-performance insulation materials in extremely compact spaces. This article will provide a deep analysis of the technical core and selection logic of this key component from an engineering application perspective.
Mainly applicable to engineering scenarios
Motor controller capacitor connection
Busbar Insulations can solve problems such as excessive parasitic inductance, significant heating, insufficient insulation distance, and high electromagnetic interference under high current and high switching frequency, ensuring stable DC bus voltage and reducing the risk of power device failure.
01
Battery management system capacitor interconnection
Automotive BusBar PET Insulation achieves low loss and high reliability connection between battery pack and filtering capacitor, improves voltage smoothness, extends battery cycle life, and adapts to long-term vehicle vibration and high and low temperature environments.
02
DC fast charging system Car Battery Bus Bar
Meet the instantaneous high current transmission requirements of high-power fast charging, reduce heat generation, improve insulation safety level, and ensure stable, efficient, and no breakdown risk during the fast charging process.
03
Connection between high-voltage distribution and onboard power supply
Implement safe wiring in dense spaces, optimize creepage distance, enhance integration, and reduce the number of wiring harnesses and connectors.
04
production process
Raw materials and processing
Conduct comprehensive inspections on core raw materials; Using high-precision CNC stamping equipment to shape and process conductors according to engineering drawings; According to the design requirements of Auto Bus Bar, the stamped conductor is bent and formed.
01
Precision hole machining and surface pretreatment
Perform high-precision drilling at designated locations; Polish the edges and surfaces of the conductor, remove burrs, avoid scratching the insulation layer, and improve surface flatness; Fine polishing of the conductor surface to optimize surface smoothness.
02
Surface treatment and integrated assembly
Automated surface treatment such as tin plating/nickel plating is applied to conductors to enhance their oxidation resistance, corrosion resistance, and contact reliability; Integrate and assemble components such as conductors, insulation layers, and protective layers to form a complete BusBar Car structure.
03
Comprehensive testing
Conduct comprehensive testing on the electrical performance, dimensional accuracy, appearance, and other aspects of the assembled New Energy Vehicle Film Capacitor BusBar to ensure compliance with design requirements; Isolate and label products that fail the inspection.
04
Finished product packaging delivery
Classify and organize qualified EV BusBars according to specifications and batches to ensure consistency in delivery; Adopting anti-static and shockproof packaging to complete product packaging.
05
Customization Process
The customer provides Busbar Insulations drawings in PDF/CAD/3D format - our company conducts process and price evaluation - after the price is approved, the customer places a sample order and pays 50% of the mold fee in advance - our company starts mold production - we provide free 1-20 sample express delivery to the customer for testing - after the sample passes the customer's test, the customer pays the remaining 50% of the mold fee - the customer issues a bulk order and pays 30% of the payment in advance - our company evaluates the delivery time and starts production - after the product is produced, we provide a packaging list to the customer and require the customer to pay the remaining 70% of the payment - our company delivers the goods according to the customer's specified payment.
contact us
Our company can provide professional product solutions and support direct technical communication with engineering teams to ensure the reliability of products in practical applications. Welcome to contact us.
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