EV Capacitor Connector BusBar
The EV Capacitor Connector BusBar is a conductive connection component specifically designed for high-voltage capacitor systems in electric vehicles (EVs). It enables efficient and safe current transfer between capacitor modules while also providing insulation protection and environmental protection, making it a critical electrical connector in the powertrain systems of new energy vehicles.
- Fast Delievery
- Quality Assurance
- 24/7 Customer Service
Product Introduction
The EV Capacitor Connector BusBar is a composite laminated conductor assembly used in electric vehicle main drive inverters to provide low-inductance, high-current electrical connections between film capacitors and power modules (such as IGBTs and SiC MOSFETs). This product typically employs a multi-layered composite structure of "conductive layer – insulating layer – protective layer," specifically designed for high-voltage (400V–800V), high-current (200A–600A), and high-temperature vibration environments, directly determining the stray inductance and heat distribution of the inverter's DC support circuit.
Material composition
Conductive Layer (Core Material)
The conductive layer is primarily composed of copper (Cu) and aluminum (Al): Copper boasts a conductivity ≥96%, high temperature resistance, and low loss, making it the mainstream material for EV high-voltage busbars and suitable for high-end, demanding applications. Aluminum has approximately 60% the conductivity of copper, is lightweight, low-cost, and recyclable, making it suitable for lightweight applications, requiring a 50% increase in cross-sectional area to match copper's current-carrying capacity.
Insulation Layer (Safety Material)
The PI film insulation layer exhibits excellent electrical properties, with a breakdown voltage ≥15kV/mm, stable dielectric constant (2.8-3.2), and good insulation performance under high temperature and high pressure, preventing leakage and short circuits. It also has a wide heat resistance range (-200℃~260℃), good tensile and bending properties, can withstand vehicle vibration and impact, and is not prone to aging and cracking for BusBar Car.
Protective Layer (Outer Protective Material)
The protective layer mainly consists of engineering plastics (such as PA66 and PC) and special coatings (such as epoxy and fluorocarbon coatings): Engineering plastics are wear-resistant, corrosion-resistant, and have excellent moldability, allowing for customized wrapping to suit most EV scenarios; special coatings are thin (0.1-0.3mm) and do not affect installation, providing busbar electric vehicle corrosion and oxidation protection, and are suitable for harsh environments.
Main advantages
Highly customizable and adaptable
The conductive layer shape and layout can be customized according to the requirements of capacitors and electrical systems, adapting to different brands and models of components. It supports single/multiple capacitor parallel connections, meeting the needs of 150-300kW EV power systems for ev battery busbar.
01
High temperature and vibration resistant
Operating temperature -40℃~150℃, it can withstand ≤10g high-frequency vibration and impact. The insulation and protective layers are not easily aged or damaged, and the New Energy Vehicle Film Capacitor BusBar's service life is ≥8 years, matching the lifespan of the entire EV vehicle.
02
High processing precision
Utilizing precision stamping and welding technology, the dimensional tolerance is ±0.05mm, and the surface flatness is ≤0.1mm. It can directly connect to terminals and power modules, supporting automated assembly, improving busbar for Power Capacitor installation efficiency and reducing labor costs.
03
Environmentally friendly and recyclable
The copper-aluminum conductive layer is 100% recyclable. The insulation and protective layers use environmentally friendly materials, free of harmful substances, complying with international environmental standards such as RoHS and REACH, aligning with global green development needs for Capacitor Busbar.
04
Selection Recommendations
System Voltage and Current
Confirm the system's rated voltage (600V, 800V, 1000V) and current (500A-2000A). Select busbar for Busbar Film Capacitor with matching rated parameters to avoid overload. For example, an 800V/250kW system requires a bar with ≥900V and ≥300A.
Conductive Material
For high-end, demanding applications, copper busbars are preferred (high efficiency and high temperature resistance). For lightweight and cost-sensitive applications, aluminum bus bars are an option, but the cross-sectional area must be matched to ensure sufficient current carrying capacity.
Installation Space and Structure
Select planar or three-dimensional EV Capacitor Connector BusBar based on the installation location layout. Choose flexible, multi-layered bars in confined spaces and rigid bars in fixed applications.
Contact Us
For customization of EV Capacitor Connector BusBar based on EV or energy storage system parameters, access to technical parameter sheets, and sample testing services, please contact us. Our professional team provides one-on-one selection guidance and solutions.
Hot Tags: ev capacitor connector busbar, China, manufacturers, suppliers, factory
