Zhejiang RHI Electric Co., Ltd.
Busbar Overmolded with Insulation for EV Motor and Battery Systems
This copper busbar is designed for EV drive systems, using PA66+GF30 for enhanced strength, heat resistance, and moldability. The material increases flexural strength by over 50% and raises the heat deflection temperature above 150 °C, ensuring stable performance under heat and vibration. Injection-molded for tight encapsulation and strong insulation, it delivers durability and reliability. Widely applied in high-voltage motors, controllers, and battery packs, insulated busbar enables compact design, high power density, automated assembly, and flexible customization for EV systems.
Description
This copper motor busbar is designed for high-performance EV drive systems, using PA66 reinforced with 30% glass fiber (PA66+GF30) for superior mechanical strength, heat resistance, and processability.
The reinforcement improves flexural strength by over 50% and raises the heat deflection temperature above 150 °C, ensuring stable performance under high temperature and vibration.
Manufactured through vertical injection molding, the copper conductor is fully encapsulated with a uniform, void-free insulation layer, delivering reliable dielectric strength and mechanical durability.
Widely applied in high-voltage traction motors, controllers, and battery packs, this electrical busbar enables compact, high-density power interconnections, supports automated assembly, and offers customizable designs for diverse EV system configurations.
| Parameter | Resisitance to High Temperature | Surface Finish | RoHS | Flammability Rating | Working Temperature | Insulation Material | Conductor Material |
| Values | 158℃/168h | Nickel plating | Qualified | UL94 V-0 | -40~105°C 125°C/180°C |
PA66 + GF30 |
T2 Copper |
Key Features
- High Mechanical Strength: 30% glass fiber–reinforced PA66 (PA66+GF30) insulation increases flexural strength by over 50%.
- Excellent Heat Resistance: Heat deflection temperature ≥150 °C ensures stability under high temperatures.
- Good Moldability: Enables precise injection molding with tight copper–insulation bonding.
- Reliable Electrical Insulation: Vertical molding eliminates air gaps for superior insulation.
- Long-Term Stability: Maintains mechanical and electrical performance under heat and vibration.
- Customizable Design: Supports tailored dimensions and layouts for different system requirements.
Applications
- High-voltage motor connections
- Energy transfer between motor controllers and battery packs
- Automated assembly of energy storage systems
