HIGH TEMPERATURE PLASTICS | MATERIALS
numerous, and also critical to the efficiency and durability of xEV batteries, motors, and power electronics,” says Parisi. “Our goal is to provide an excellent material for the application, along with assisting customers in their bus bar design and overmoulding, to help them achieve their perfor- mance and production goals.” Laminated metal bus bars are found in virtually every xEV system, says DuPont. These bus bars transfer electrical energy from high-power battery packs to inverters, which convert the energy to AC electricity. Bus bars are being developed to help xEV batteries’ thermal management and power distribution systems. They must be adequately insulated in case the battery overheats and goes into thermal runaway. Qualification of new materi- als is carried out using demanding thermal cycling and electrical tests. DuPont has developed a refined overmoulding
process for bus bars using Zytel HTN material, for which the company offers technical and processing support. Using computer-aided analysis tools, the company collaborates with customers to reduce manufacturing time and cost, while maintaining performance and safety standards. For example,
safety standards dictate that bus bars maintain a stable orange colour indicating high voltage, even after repeated exposure to high heat. Zytel HTN accelerated aging testing shows no noticeable colour shifts, even at 130°C. It also contributes insulative properties for safer thermal runaway, and easily overmoulds onto aluminium or copper. DuPont says Zytel HTN insulation materials for bus bars resist multiple thermal shock cycles (typically 1,000 cycles) at temperatures from -40°C to 150°C which are normally needed for motors and power electronics applications. This means the
Above: DuPont says a combination of its Zytel HTN material, processing support and technical exper- tise raises the performance of ubiquitous bus bars
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