Copper Busbar Overmolding Motor Connections
In EV drive motors, energy storage inverter motors, and industrial servo systems, electromagnetic coils serve as essential components for power transfer. Enamelled wires, acting as conductors, must provide reliable insulation while maintaining mechanical stability. To ensure optimal performance at lead-out points, including improved sealing, reinforced structural strength, and long-term operational reliability, the overmolding process for enamelled wires has become a critical solution. By integrating insulation, mechanical support, and precise dimensional control in a single step, overmolded busbars effectively prevent electrical faults and enhance durability in high-voltage, high-current applications typical of modern electric vehicles and energy storage systems.
Process Principles & Benefits
The overmolding of enamelled wires encapsulates lead-out points in custom molds, forming a single, integrated insulation layer. This approach ensures both electrical safety and structural integrity.
1. Superior Insulation
By combining the molded layer with the enamel coating, the busbars achieve enhanced dielectric performance, suitable for high-voltage applications.
2. Mechanical Reinforcement
The molded section firmly holds the wire leads, reducing the risk of displacement caused by vibration, pull forces, or thermal expansion during operation.
3. Environmental Protection
Complete encapsulation prevents moisture, dust, and condensation from entering, improving durability and reliability under harsh conditions.
4. Automation Compatibility
The overmolding process is highly controllable and repeatable, making it ideal for integration with automated winding and welding systems for consistent, large-scale production.
Specifications
| Parameter | Resisitance to High Temperature | Insulation Withstand Voltage | RoHS | Flammability Rating | Working Temperature | Insulation Material | Conductor Material |
| Values | 158℃/168h | AC 1000V | Qualified | UL94 V-0 | -40~105°C 125°C/180°C | PA66/PPS/PA6T/PBT/PPA +GF | T2 Copper/Aluminum |
Why Choose RHI?
RHI is a trusted Chinese manufacturer specializing in copper and aluminum busbars, delivering tailored connection solutions for new energy battery systems. With advanced engineering expertise and strict quality management, we provide dependable products to customers worldwide.
Core Competencies
1. Scalable Manufacturing
Our 30,000+㎡ modern facility is equipped with fully automated production lines, enabling high-volume, consistent output to meet growing industry demand.
2. Precision & Quality Assurance
Through automated processes supported by CCD inspection, we implement multi-level quality control. Certifications including IATF 16949, ISO 14001, and ISO 45001, along with compliance to RoHS, REACH, and UL94V-0 standards, ensure international reliability.
3. Smart Manufacturing Systems
Integrated ERP, PLM, and MES platforms drive digitalized management, improving efficiency, consistency, and cost competitiveness.
4. New Energy Focus
Our busbars are engineered for high conductivity, heat resistance, and safe performance in EV batteries and energy storage. Recognized in 2023 as a “Specialized & Innovative SME,” we continue to advance solutions for the evolving new energy sector.
Our Commitment
By combining manufacturing excellence with innovation, RHI supports the global shift toward sustainable energy through reliable, high-performance busbar technologies.
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