Insulated Busbar: Technological Innovation And Industrial Breakthrough Path in The Field Of Energy Transmission
Mar 21, 2025
Under the dual waves of the smart grid and the new energy revolution, the insulated busbar, as the core carrier of the power distribution system, is undergoing a strategic upgrade from traditional distribution components to intelligent integrated modules. This key component not only carries the mission of efficient transmission of electric energy but also becomes the core supporting component in the fields of new energy vehicles, ultra-high voltage transmission, industrial automation, etc. in the technological evolution of high voltage, lightweight, and modularization.
1. Application scenario iteration: deep penetration of the new energy track
The application map of insulated busbars is accelerating in the new energy field:
New energy vehicle three-electric system: Under the 800V high-voltage platform architecture, the integrated busbar (CCS) achieves a 30% increase in battery pack space utilization through an all-in-one design. The Laminated Flexible BusBar equipped with the latest Kirin battery released uses nano-silver sintering technology to reduce the internal resistance of the module by 15%, adapting to the 4C supercharging requirements.
Energy storage and hydrogen equipment: In electrochemical energy storage containers, PVC Coated Bus Bars (salt spray resistance ≥1000h) ensure stable operation in a wide temperature range of -40℃~+60℃. The bipolar plate busbar connection solution developed by a leading hydrogen energy company achieves a voltage uniformity error of less than 2%, which helps the commercialization of kilowatt-level fuel cell systems.
High-end manufacturing scenarios: In industrial robot servo systems, special-shaped Epoxy Powder Coating Insulated Busbars (minimum bending radius 3mm) solve the problem of high-density wiring, and with digital-performing technology, the assembly efficiency is increased by 40%. Data shows that the market share of industrial busbars in the field of precision manufacturing will reach 28% in 2025.
2. Technological evolution: driven by material revolution and structural innovation
The industry is undergoing a transformation from a "single functional component" to a "system-level solution":
▶ Material system breakthrough
Third-generation semiconductor adaptation: Aluminum nitride ceramic-based busbars supporting silicon carbide (SiC) modules achieve a 50% reduction in thermal resistance (<0.1℃·cm²/W), meeting the high power density requirements of 1700V/3000A
Composite conductive materials: The large-scale application of graphene-modified copper-aluminum composite materials (conductivity ≥98%IACS) reduces the weight of the Insulated Copper Bus Bar by 25% while maintaining the current carrying capacity
Environmentally friendly insulation system: Halogen-free silane cross-linked polyethylene (XLPE) insulation layer (oxygen index > 34) has passed UL94 V-0 certification, replacing the traditional epoxy resin system
▶ Structural design innovation
| Technical direction | Typical cases | Performance improvement |
| Three-dimensional molding | Tesla 4680 battery pack serpentine busbar | Space utilization ↑45%, stray inductance ↓30nH |
| Intelligent sensor integration | NARI digital busbar (built-in temperature sensor) | Real-time monitoring accuracy ±0.5℃ |
| Anti-vibration design | CRRC Group high-speed rail traction system busbar (fatigue life 10⁷ times) | Adapt to 30m/s² vibration environment |
3. Industrial ecological reconstruction: domestic substitution and global layout
In 2025, the industry showed significant structural changes:
Supply chain reshaping: Domestic companies have made breakthroughs in key processes. The vacuum pressure impregnation (VPI) technology of the company has increased the insulation withstand voltage to 60kV (traditional process 35kV), breaking the monopoly of European and American companies in the high-voltage busbar field.
Market pattern evolution: The new energy vehicle Insulating Coatings Busbar market has formed a "tier1+material supplier" collaborative model. The automotive-grade busbar jointly developed by BYD Semiconductor has passed the IATF16949 certification and is equipped with more than 20 models.
Global layout: Hytera and other companies quickly acquired high-voltage busbar (110kV level) design capabilities through mergers and acquisitions of old European busbar manufacturers (such as Germany's Mersen subsidiary) and participated in the construction of photovoltaic energy storage projects in the Middle East
4. Future trends: standard leadership and scenario extension
The industry faces three strategic opportunities:
1. Standard system construction: The national standard "Technical Specifications for High-voltage Busbars for New Energy Vehicles" (draft for comments) clarifies 12 core indicators such as temperature rise and withstand voltage, and promotes the unification of product specifications
2. Emerging scenario development:
Rail transit: The permanent magnet synchronous motor busbar system developed by CRRC Sifang has achieved its first commercial application in Qingdao Metro
Aerospace: The titanium alloy busbar used in the power distribution system of the C919 domestic large aircraft has passed the 2000h salt spray test (national military standard GJB150.11A)
3. Digital transformation: The application of digital twin technology in busbar design has shortened the R&D cycle by 40%.
5. Challenges and countermeasures: quality control and sustainable development
There are two core pain points in the current industry:
Quality consistency problem: Laminated Inverter Busbars welding defect rate (industry average 0.8%) restricts high-end applications, laser welding + AI visual inspection solution (defect detection rate 99.97%) becomes the key to breaking the deadlock
Green manufacturing pressure: The EU RoHS 3.0 directive promotes enterprises to adopt a chromium-free passivation process, and the phytic acid passivation technology developed by a listed company (in compliance with OEKO-TEX 100 certification) has been mass-produced
The response strategy presents three major directions: ①Build a full-chain quality system of "material-process-testing" ②Develop recyclable busbars (disassembly recycling rate>95%) ③Layout carbon footprint certification (ISO 14067)
Industry insights: three dimensions of value upgrade
From the analysis of the industry value chain, insulated busbar companies are achieving leaps from three levels:
1. Product dimension: From a standard parts supplier to a customized solution service provider (such as providing "busbar + fuse + sensor" integrated module)
2. Technical dimension: Master the "material-simulation-manufacturing" core technology closed loop, the Dip Insulated Busbar electric field simulation software independently developed by a certain enterprise (error <3%) has obtained software copyright
3. Ecological dimension: Build a "busbar-energy storage-intelligent operation and maintenance" industrial ecology, and the busbar health management system of Guodian Nanzhong has been connected to 100+ substations of the State Grid
Conclusion: The power connection revolution in the new energy era
Under the guidance of the "dual carbon" goal, the Insulating Coatings Busbar industry is performing a deep integration of material science, manufacturing technology and application scenarios. When 3D printed busbars (minimum thickness 0.1mm) break through the traditional manufacturing boundaries, and when silicon carbide busbar modules support megawatt-level power conversion, this seemingly niche field is reshaping the future of energy transmission. For Chinese companies, only by grasping the three golden tracks of new energy vehicles, energy storage, and ultra-high voltage and building a competitive barrier of "technology + standards + ecology" can they occupy a dominant position in the global energy transformation wave.
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