Next generation component revolution! At the forefront of electrical connections made possible by busbar forming technology

In recent years, demand for highly efficient and reliable electrical connection components has increased rapidly in line with the spread of electric vehicles (EVs), renewable energy and industrial electrical systems. One technology that has attracted particular attention is known as ‘busbar molding’. This article details the basics, processes, fields of application, technical benefits and challenges of busbar molding.

What is busbar molding?

Busbars are conductive components for the efficient distribution of electrical current, often made of copper or aluminium. Busbar molding is the process of molding resin into these busbars to insulate and protect them. Also called busbar insert molding.

Busbar molding is a technology that unites different properties - conductivity and insulation - by means of injection molding. This technology enables components with high electrical performance and physical strength to be manufactured efficiently.

Busbar molding process

The production process for busbar molding mainly consists of the following steps

1. preparation of the busbar material

Busbars are usually processed from copper or aluminium sheet material. The shape of the conductor part is produced by laser machining or stamping, depending on the circuit design and application. 2.

2. selection of resin

Resins are required to provide insulation and heat resistance, and epoxy, polycarbonate and nylon are often used. Materials with high voltage resistance are selected, especially for high voltage applications.

3 Injection molding

Injection molding machines are used to mold the resin into the busbar part, which serves as the conductor. The mold is designed so that the busbar is properly held in the mold and the resin flows in evenly.

4. cooling and removal

After molding is complete, the product is cooled and removed from the mold. The molded product has a structure in which the conductive and resin-insulating parts of the busbar are integrated.

Advantages of busbar molding

Busbar molding technology offers a number of advantages, such as

1. improved insulation and protection

Moulding the resin into the busbar ensures excellent insulation. This improves safety even in high-voltage circuits. The resin also acts as protection against external shocks, moisture and dirt.

2. lightweight

By combining lightweight conductors such as aluminium with thinly molded resin, the weight can be significantly reduced compared to conventional cabling. This is particularly important for electric vehicles and aircraft.

3. compact design

Busbar molding allows complex shapes to be integrated compactly. This saves wiring space and increases design freedom.

4, mass-producibility and cost-efficiency

Using injection molding, components with complex geometries can be mass-produced with high precision and cost-efficiency.

Fields of application

Busbar molding technology is used in a wide variety of fields of application, such as

1. electric vehicles (EV)

In battery modules, inverters and charging systems, busbar molding provides reliable electrical connections.

2. renewable energy

Highly efficient current distribution in photovoltaic and wind power installations.

3. industrial equipment

Used in electrical wiring in factories and in the internal circuits of large machines.

4. medical equipment

Also used in the internal wiring of medical equipment where reliability is required.

Busbar molding issues and countermeasures

Busbar molding has many advantages, but there are also some challenges.

1. adhesion between resin and metal

Delamination can occur at the joint between the metal conductor and the resin. This may result in reduced electrical performance and durability.

Solution: roughen the conductor surface or use a primer to improve adhesion.

2. eccentricity caused by busbar deformation

When injection pressure is applied, the busbar in the mold is deformed, causing the wall thickness to be biased towards the resin flowing first. This may result in fracture or exposure of the busbar from thin-walled parts.

Solution: add pins to the mold to hold the busbar in place where injection pressure is applied. The busbar will be exposed at the retained point, but this will reduce the thickness of the busbar.

3. difference in thermal expansion

Due to the different thermal expansion coefficients of metals and resins, stresses may occur in high temperature environments, resulting in deformation and cracking.

Solution: select materials with similar thermal expansion coefficients or adopt a design that disperses stress.

4. cost increase

Initial costs may be higher due to the need to design molds and select special materials.

Countermeasure: To reduce the initial investment, the molding process should be optimised to improve the material yield.

Conclusion.

Busbar molding technology is an integral part of modern electrical connection component manufacturing. Its insulating properties, light weight, compactness and mass production efficiency enable its use in a wide variety of fields. At the same time, advanced technology is required to deal with adhesion and thermal expansion challenges.

In the future, busbar forming technology will play an increasingly important role in growth areas such as electric vehicles and renewable energy. Advances in technology are expected to bring higher-performance, cost-effective products to the market.