Copper Busbar with PA12 Extruded Insulation for EV & Electrical Applications
Made from T2Y2 hard copper with ≥98% IACS conductivity, the copper busbar features a precision rectangular profile and stable mechanical performance under vibration and thermal cycling conditions. Chamfered edges help optimize electric field distribution and reduce the risk of partial discharge and creepage in high-voltage applications. The low-smoke halogen-free PA12 insulation is applied through integrated extrusion molding, providing high dielectric strength and reliable electrical insulation. With a continuous operating temperature range of 105–125°C, the busbar is suitable for EV battery packs and energy storage systems.
PA12 extruded rigid copper busbar features seamless, bubble-free insulation, wide temperature resistance, oil and vibration resistance. The thin low-smoke halogen-free PA12 layer provides high dielectric strength and UL94 V-0 flame retardancy while maintaining heat dissipation. With strong mechanical durability and anti-creep performance, it is suitable for EV battery packs and energy storage high-voltage connections.
Product Features
- Conductive Material Performance: Made from T2Y2 tough pitch copper with ≥98% IACS conductivity, the copper busbar features a precision rectangular profile, low electrical loss, and stable mechanical performance under vibration and fatigue conditions.
- High-Voltage Field Optimization: Chamfered and edge-treated ends reduce electric field concentration, helping minimize partial discharge and creepage risks in high-voltage applications.
- PA12 Insulation Protection: The low-smoke halogen-free PA12 insulation is applied through continuous extrusion molding, providing high dielectric strength and reliable electrical isolation.
- Wide Temperature Operation: Designed for continuous operation at 105–125°C, the busbar is suitable for EV battery PACKs and energy storage systems under thermal cycling conditions.
| Parameter | Withstand Voltage | RoHS | Insulation Material | Temperature Resistance | Insulation Thickness | Conductor Material |
| Values | DC 4000 V, 1 min | Qualified | PA12 extrusion layer | 150°C | 0.4-0.8mm | T2Y2 copper |
Application
The rigid copper busbar is manufactured through integrated processes including cutting, extrusion molding, bending, punching, and chamfering, ensuring precise dimensional control and stable assembly for automated production lines.
EV Battery Applications: Designed for battery module interconnections, the busbar provides vibration resistance and thermal cycling durability. Combined with low-smoke halogen-free insulation and chamfered edge treatment, it helps reduce partial discharge risks and supports high-voltage safety under vibration, fast charging, and temperature rise conditions.
Energy Storage Applications: The integrated extruded insulation structure provides moisture protection and electrical isolation. With low electrical loss and high current-carrying capability, the busbar is suitable for outdoor ESS systems operating under large temperature variations and continuous high-power charge/discharge conditions.
Vehicle Electrical Control Applications: The rigid and compact design enables space-efficient high-voltage connections inside power control units. The wear-resistant insulation layer improves protection performance and reduces heat generation during high-frequency current operation.
