Heat-Resistant Ceramic Tape Busbars for EV Batteries
RHI develops copper busbars insulated with ceramic composite tape, utilizing ceramic fibers engineered for exceptional thermal stability, dielectric strength, and structural reliability in demanding electric vehicle applications.
Through automated precision winding, each busbar conductor is wrapped with consistent tension and adhesion, ensuring reliable insulation and superior heat resistance. These custom busbars provide a dependable solution for high-voltage interconnections in next-generation EV battery systems.
Process Features
High-Performance Materials
The ceramic composite tape is produced from advanced ceramic fibers, delivering dependable heat shielding and electrical insulation for high-voltage interfaces in demanding EV conditions.
Automated Wrapping
Precision winding systems apply the tape with optimized tension and alignment, ensuring consistent coverage and firm bonding. This process secures insulation stability, enhances thermal endurance, and minimizes the risk of layer separation.
Click here to view the automated winding process.
Product Benefits
Thermal Reliability: Operates safely under elevated temperatures, helping to control thermal runaway.
Electrical Safety: Strong dielectric properties reduce leakage and improve system reliability.
Mechanical Durability: Resists tensile stress, bending, and impacts, supporting complex pack assembly.
Chemical Stability: Maintains performance under corrosive environments, prolonging service life.
Installation Versatility: Suitable for different busbar designs, enabling efficient integration into EV systems.
Technical Specifications
Flame resistance: withstands 1000 °C for 10 minutes
Dielectric strength: 3500 V DC / 60 s, leakage current <1 mA
Insulation resistance: 1000 V DC / 60 s, >500 MΩ
Configurations: available in rigid and flexible busbar formats
Application
With its strong thermal endurance and reliable dielectric performance, this ceramic tape–insulated busbar technology is applied in high-voltage pathways of electric vehicle battery packs. It is particularly suited for environments where elevated temperatures, compact layouts, and stringent insulation demands challenge system reliability.
Beyond battery modules, these battery busbars are also integrated into energy storage units, DC distribution systems, and charging infrastructure, where stable conductivity, safety, and long service life are critical. Their adaptability to both rigid and flexible configurations makes them an efficient solution for next-generation power architectures in the new energy sector.
