E-MOBILITY
Overmoulded busbars are made up of high-voltage components that combine plastic with copper alloys
OVERMOULDED BUSBARS
How overmoulded busbars are powering the future in modern electric transportation applications
T
he integration of overmoulded busbars into modern electrical applications has
revolutionised the way we approach electrical connectivity and power distribution in automotive and industrial applications. These components are now essential for connecting the battery to the inverter and into the motor. Here, we discuss the basics, benefits and production of overmoulded busbars.
ROLE AND CHALLENGES OF OVERMOULDED BUSBARS From the beginning of e-mobility, overmoulded busbars have been indispensable in various electrical applications due to their ability to provide reliable and efficient connections. The constant aim to
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increase efficiency of the drivetrain causes ever greater power density, which leads to higher requirements for the connections between batteries, DC- to-AC power inverters and AC traction motors. This trend has a huge impact on the design of the connectors. With higher power density the form
factors of the copper busbars and the conductive surface areas need to be increased without violating the limited installation space. Additionally, the reduction of air and creep phenomena is key to prevent breakdown of insulation and to limit loss in power. Increasing junction temperatures is also a challenge and must be considered in the design of the connectors, polymer selection and sealing technique. All these increased requirements must be met, without neglecting the weight, size, and the feasibility of the overmoulded busbars.
UNPACKING THE BENEFITS The advantages of overmoulded busbars are numerous. Their design allows complex geometries that are crucial in today’s compact electronic devices. This capability ensures excellent form and positional accuracy, enabling precise and reliable connections. Additionally, the high energy densities achievable with overmoulded busbars make them ideal for applications where space is limited but power requirements are high. The evolution from traditional
wound stators to hairpin technology has had a significant impact on busbar design. Hairpin stators, with their precise and compact shape, improve the overall efficiency and power density of electric motors. This evolution has led to improvements in busbar manufacturing and assembly
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