Copper Busbar with Ceramic Tape Insulation and PVC Dip Coating for EV Battery Packs
Dual-insulated copper busbars with PVC dip coating and ceramicized composite tape, 3D-formed for precision routing. High-conductivity copper reduces transmission losses, while the insulation system ensures high dielectric strength, corona resistance, and long-term thermal stability. The copper bus bar is optimized for 400V–800V fast-charging EV battery packs and energy storage systems, enabling safe, low-rise, high-efficiency high-voltage power distribution.
Product Description
Rigid copper busbar with dual insulation of PVC dip coating and ceramic composite tape, formed by CNC-integrated 3D bending. High-conductivity copper reduces HV transmission losses and temperature rise under fast charging. Ceramic composite insulation provides high dielectric strength, corona resistance, and high-temperature flame retardancy. 3D forming eliminates segmented joints, lowering contact resistance and enabling compact integration.
Compatible with 400V systems and optimized for 800V fast-charging platforms, it effectively mitigates overheating, insulation failure, and assembly complexity, meeting automotive-grade high-load, high-frequency charging requirements.
Key Features
- Material: High-purity rigid copper busbar with high conductivity, reducing power loss and temperature rise.
- Insulation: PVC dip coating combined with multi-layer ceramic composite tape, offering high dielectric strength, corona resistance, and thermal stability.
- Process: CNC 3D one-piece bending, no joints, lower contact resistance, easier assembly.
- Compatibility: Supports 400V systems and optimized for 800V fast-charging EV battery packs.
- Reliability: Automotive-grade design for high-load, high-frequency fast charging with improved HV safety.
| Parameter | Withstand Voltage | RoHS | Insulation Material | Temperature Resistance | Insulation Thickness | Conductor Material |
| Values | DC 4000 V, 1 min | Qualified | PVC Dip Coating | -40~125°C | 0.8-2mm | T2Y2 copper |
Application
The custom busbar is designed for high-voltage EV power applications and compatible with mainstream CTP/CTC battery pack architectures. It supports key internal connections including HV distribution, cell-to-module series connection, and circuit conduction, meeting compact EV battery design requirements.
Widely used in passenger EVs, commercial vehicles, and energy storage systems, battery busbar covers both BEVs and high-power storage applications.
Compatible with 400V platforms and optimized for 800V fast-charging systems, enabling a smooth upgrade path and providing a safe, low-loss, highly compatible, and easy-to-assemble HV interconnection solution.
