Powder Coating EV Busbars
Powder coating EV busbars are electrical interconnect components made of high-purity copper as the substrate, which are formed by electrostatic spraying of epoxy powder and high-temperature curing. It is mainly used in high-voltage battery systems, thin film capacitors, power relays, drive controllers, and power distribution units (PDUs) of new energy vehicles (EV/PHEVs) to undertake high current and high voltage power transmission tasks.
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Product Introduction
Powder coating EV busbars are customized power transmission core components designed specifically for high-voltage systems of new energy electric vehicles and hybrid vehicles. It uses high-purity copper as the conductive substrate and forms a dense protective layer through various insulation processes such as epoxy powder coating. It combines the high conductivity of copper substrate with the safety protection characteristics of insulation materials, completely solving the industry pain points of insufficient insulation reliability, poor space adaptability, weak vibration tolerance, low environmental weather resistance, and high operation and maintenance costs in traditional EV high-voltage distribution systems.
Product Advantages
Electrical Safety Advantages
The powder coating has no air gaps or pinholes. After high-voltage spark testing (100% full inspection), the Powder coating EV busbars can stably withstand 5000 VDC withstand voltage testing, significantly reducing the risk of internal short circuits in the battery pack.
01
Thermal Management Advantages
Epoxy coating has a certain thermal conductivity, combined with the low resistance characteristics of high-purity copper (≤ 0.00001 Ω), and the temperature rise can be controlled under high current conditions.
02
Space utilization advantages
The coating thickness of Insulated coating busbar is only 150-300 μ m, which saves a lot of space compared to PA66 shell (usually 1.5-3mm), and has irreplaceable advantages in small areas such as cell gaps and capacitor terminals.
03
Environmental resistance advantages
Epoxy coating has good resistance to moisture, salt spray, electrolytes, engine oil, etc. Epoxy powder coating insulated busbars meet the stringent chemical resistance testing requirements of the automotive industry.
04
Manufacturing Advantage: Balancing Scale and Flexibility
Capacity and Delivery
The monthly production capacity of Epoxy powder spraying is 50 million pieces, and the flexible production line supports seamless switching between small batch (MOQ starting from 500 pieces) and large batch modes. Standard orders can be delivered within 7-10 days, while sample orders can be completed within 10-20 days (including tooling/mold development). Provide 1-10 free samples to reduce customer selection risks.
Process capability
The stamping accuracy of the Powder coated busbar is ± 0.05mm, the bending angle tolerance is ± 0.5 °, and the welding tension is ≥ 80% of the base material. Surface treatment coating 3-12 μ m controllable, uniformity ± 10%. The accuracy of insulation coating thickness is ± 0.05mm, and the assembly torque control is ± 5%.
Quality assurance
Passed ISO9001, IATF16949, RoHS, and REACH certifications. Full chain traceability: raw material furnace number → plating solution batch → coating parameters → finished product serial number. Test the conductivity, temperature rise, bending, insulation withstand voltage, salt spray, and flame retardancy of Busbar coating with epoxy coating powder.
Engineering Support Capability
Assist clients in optimizing the structure of the Insulated copper bus bar to make it more suitable for powder coating processes (such as avoiding sharp corners, optimizing suspension points, etc.)
Based on voltage level, current size, and environmental conditions, recommend the most suitable insulation type and thickness.
We can provide Insulation coating busbar withstand voltage test reports, insulation resistance test reports, temperature rise test data, and coating thickness reports.
In case of assembly or welding issues with the customer's Powder coating EV busbars production line, we will respond and provide solutions within 24 hours.
contact us
If you are developing a new generation of fuse products or wish to optimize the assembly process of existing fuses, please feel free to contact us. We can provide engineering support such as free samples of Bright Tin-plated fuse copper cap, drawing reviews, and assembly compatibility verification.
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