Injection molding technology applies molten plastic onto copper busbars to form an insulating layer, providing both reliable electrical insulation and mechanical protection. These electrical busbars are widely used in switchgear, new energy systems, and other critical applications.
Overmolded Busbars for EV Battery & Motor Connections
Injection molding technology applies molten plastic onto copper busbars to form an insulating layer, providing both superior electrical insulation and mechanical protection. It is widely used in switchgear, new energy systems, and other critical applications.
Material Selection Criteria
Thermoplastic engineering plastics are preferred, with evaluation based on the following properties:
PA6/PA66: Excellent mechanical strength and impact resistance; with 15–30% glass fiber reinforcement, flexural strength increases by over 50% and heat deflection temperature exceeds 150 °C.
PPS: Extremely low water absorption (0.02%); ideal for high-temperature, high-humidity, and chemically aggressive environments.
PBT: Outstanding electrical insulation and chemical resistance; suitable for humid or oil-exposed conditions.
PP: Cost-effective option with limited heat resistance; recommended for low-power applications.
Technical Performance Requirements
Appearance Quality: Smooth surface, free from burrs, flow marks, or short shots.
Insulation Properties:
• Thickness tolerance: ±0.2 mm, minimum ≥90% of nominal value
• Dielectric strength: ≥10 kV/mm (1 min without breakdown)
• Insulation resistance: ≥500 MΩ (1000 V DC)
Mechanical Properties:
• Pass 90° bending test (r = 3t)
• Impact strength ≥20 kJ/m²
• Tensile strength ≥40 MPa
Environmental Reliability:
• After aging at 120 °C × 1000 h, insulation resistance retention ≥80%
• Pass 85/85 test with dielectric strength degradation ≤20%
| 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/Al |
Applications
New Energy Vehicle Motors: Critical for winding connections, requiring exceptional heat resistance and mechanical strength.
Power Battery Systems: Cell connection components that must ensure both high conductivity and corrosion resistance.
Technical Features
Integrated insulation encapsulation for significantly enhanced reliability
Compatible with automated mass production with high consistency
Proven long-term performance under harsh environmental conditions
This solution is particularly suited for new energy and power electronics sectors with stringent reliability demands, providing essential assurance for safe system operation.
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