Producing Busbar by Extrusion for Electric Vehicles with Rilsan® Polyamide 11
A busbar is a rigid electrical interconnection metal bar coated with an insulative layer, applied through extrusion, ensuring excellent electrical resistance, and durability across -40 to 125°C. The PA11-coated busbars help to achieve flame resistance without degradation of appearance, electrical properties, flexibility for bending.
What is a busbar?
A busbar is a rigid conductor with a rectangular profile, unlike conventional round cables. This shape allows it to fit seamlessly into vehicle designs while efficiently transmitting high currents to power components like batteries and electric motors. Its design offers key advantages, including improved energy efficiency, better thermal dissipation, space savings, and reduced assembly costs.
Since busbars carry high currents, proper insulation is essential to prevent electrical arcing. The insulative layer is applied through extrusion, ensuring excellent electrical resistance, and durability across -40 to 125°C. The automotive industry has standardized an orange color (RAL 2003) for easy identification and safety. While traditional heat-shrink sleeves have been used, more advanced insulation methods—such as crosshead extrusion, injection molding, and powder coating—now offer improved efficiency, flexibility, and performance.
Case study on busbar with Rilsan® PA11
With the rapid growth of electric vehicles, the demand for advanced battery and fast-charging technologies is increasing. New EV designs require optimized space utilization, higher voltage and amperage, improved heat dissipation, reduced weight, and streamlined assembly. In this case study, we explore how busbars help overcome these challenges by enabling more compact, efficient, and lightweight electric powertrain components.
