EV BusBars
EV BusBars are conductive connection components used to achieve high current power transmission in the electrical system of electric vehicles. This product is usually formed from metal conductors such as copper or aluminum through stamping, bending, surface treatment and other processes, and is covered with insulating materials at key parts to form an electric energy distribution path with low resistance and high current carrying capacity.
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Product Introduction
EV BusBars
EV BusBar is a flat conductor integrated in high-voltage electrical systems. It is usually superimposed or composited with multiple layers of high-conductivity materials. It replaces some traditional cables to achieve stable connections between battery modules, between batteries and controllers, and between high-voltage components.
Product properties
Our EV busbar products demonstrate superior engineering attributes based on a deep understanding of high-voltage electrical characteristics.
High current carrying and low impedance characteristics
The busbar for Busbar Film Capacitor uses high-purity oxygen-free copper (T2/C11000) or high-performance aluminum alloy as the conductive base material. Through optimized cross-sectional design, it ensures that the temperature rise under high current conditions is controlled within a safe range.
01
Excellent insulation and voltage resistance properties
For 800V high-voltage platforms, the product adopts a double-layer insulation protection system. The inner layer is coated with high-temperature-resistant, high-dielectric-strength polyimide or modified epoxy resin, and the outer layer can be optionally injection-molded with high-performance engineering plastics (such as PPS/PPA).
02
High mechanical strength and shock resistance
Considering the vibration and impact during vehicle driving, the ev battery busbar has extremely high mechanical rigidity. The support structure design optimized through finite element analysis (FEA) enables it to maintain zero looseness and zero breakage during high-frequency vibration tests, ensuring the long-term reliability of the connection points.
03
Integrated design
The New Energy Vehicle Film Capacitor BusBar supports the integration of signal acquisition lines, temperature sensors and high-voltage connection points to achieve synchronous transmission of "power + signal", greatly simplifying the vehicle wiring harness layout and improving assembly efficiency.
04
Manufacturing Advantage
The busbar is not a precision mechanical part, but it requires extremely high process consistency.
Stamping-bending-insulation integrated streamline
Reduce transfer and secondary positioning errors for Tin Plated Copper BusBar for EV.
Bending springback closed loop compensation
Each batch is sampled to detect the bending angle, and the springback compensation coefficient is embedded in the mold parameters.
Local controllable removal technology of the insulation layer
Only remove the insulation layer on the terminal surface that needs to be conductive, and the edges will be neat and burr-free for Busbar Insulation.
100% continuity and withstand voltage testing
It's not a random inspection; it's a red line at the end of the process for the capacitor laminating bus bar.
Production process
Material pretreatment
Cleaning and annealing of high-conductivity copper/aluminum strips to improve ductility and conductivity for Capacitor Busbar.
Precision stamping
High-speed punching machine combined with a carbide mold to achieve ±0.05mm dimensional accuracy and burr-free edges for DC Capacitor Busbar.
Stack welding
Laser welding or diffusion welding is used to achieve a reliable connection between layers with resistance below 0.1mΩ.
Surface treatment
Optional tin plating, silver plating or nickel plating to enhance corrosion resistance and weldability for Tin-plate Busbar Automotive.
Insulation encapsulation
Achieve a uniform insulation layer and high sealing through potting, molding or overmolding for busbar electric vehicle.
Inspection and aging
100% electrical testing (withstand voltage, insulation resistance, contact resistance), three-dimensional scanning and high and low temperature cycle aging.
Why choose us
We do not provide "universal busbars."
But provide customized designs specific to your installation boundaries and assembly processes for DC Capacitor Busbar.
Do not avoid technical problems
Vibration, temperature difference, creepage, and special-shaped space for Tin Plated Copper BusBar for EV.
Rapid engineering response
Drawing review → DFM report → sample → small batch, controllable rhythm for Busbar Insulation.
Process document traceability
Each batch includes dimensional reports, insulation withstand voltage records, and electroplating layer verification.
contact us
What we provide is not just standardized busbar parts, but in-depth engineering solutions based on EV BusBars. We aim to help you stand out in stringent supply chain audits through ultimate reliability and system integration. We sincerely invite you to discuss technical details with us through the inquiry channel below.
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