High-Voltage Copper Busbar for EV Battery Pack and Drive Motor
The insert-molded busbar is engineered for new energy systems, including battery packs, drive motors, and ECUs. Copper busbar allows for customized tooling and plating. The PA66+GF30 insulation provides excellent mechanical strength, heat resistance (HDT > 250 °C), and formability. Featuring over 50% greater flexural strength, the insulated busbar maintains reliable electrical and mechanical stability even under high-temperature and high-vibration conditions.
In EV battery packs, overmolded copper busbars serve as the core components for high-voltage current transmission. Through precision molding, high-performance engineering plastics are tightly encapsulated around copper conductors to form an integrated conductive structure. These electrical busbars enable reliable high-current transfer while providing dense insulation for high-voltage protection. Structurally, they offer impact resistance, vibration durability, and long-term mechanical stability, effectively replacing dispersed wiring to optimize space utilization and assembly efficiency. The insulation material must deliver excellent dielectric strength, high mechanical toughness, and long-term thermal stability, along with superior flowability for precise encapsulation of thin and complex geometries. Special formulations ensure strong copper–plastic bonding, preventing delamination and ensuring long-term reliability.
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| Parameter | Insulation Withstand Voltage | RoHS | Flammability Rating | Operating Temperature | Insulation Material | Conductor Material |
| Values | AC 1000V | Qualified | UL94 V-0 | -40 °C–120 °C (max 150 °C) |
PA66 + GF30 |
T2 Copper |
Core Functions and Design Advantages
- High-Voltage Conductivity: Made with high-purity copper conductors to ensure low resistance and excellent conductivity. Capable of stably transmitting hundreds of amperes within the battery pack’s high-voltage circuit, powering key units such as drive motors, BMS, and high-voltage relays.
- Reliable Electrical Insulation: The injection-molded insulation layer fully isolates the conductor from the environment, meeting IEC 60664 and ISO 6469 high-voltage safety standards. Insulated busbar prevents creepage, breakdown, and short-circuit risks, greatly enhancing system safety.
- Mechanical and Thermal Stability: The molded insulation offers high strength and vibration resistance, effectively absorbing assembly and operating shocks to prevent conductor fatigue, loosening, or breakage, ensuring long-term reliability.
- Compact Design and Assembly Efficiency: Replacing traditional wiring harnesses, the custom busbar integrates conduction, insulation, and mounting into a single structure, reducing components and assembly steps while optimizing space and routing within the battery pack.
- Automation Compatibility: With standardized geometry and high positioning accuracy, the structure supports automated assembly and inspection, improving production consistency and yield.
