High Voltage Busbar Specifications and Models

High-voltage busbars come in various models including overmolded, laminated, PCB-based, and high-current connector types, designed for automotive, rail, and industrial applications.

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E Connectivity BusbarsTE Connectivity offers high-voltage busbars for rail and electric vehicle applications, often featuring Bus Bar Insulation Tubing (BBIT) for additional insulation. These busbars are designed for short-distance HV connections, particularly near pantographs and circuit breakers, and can include support insulators for robust mounting.

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E also provides U-connector and L-joint connectors for inter-car high-voltage connections on locomotives and EMUs, ensuring safe and maintenance-free operation. Automotive Overmolded BusbarsM.

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C develops overmolded busbars for automotive high-voltage systems, connecting the battery, control unit, drive, and charging components. These busbars are designed to maximize space efficiency, ensure adequate insulation, and protect personnel from accidental contact. They are typically manufactured using multi-stage processes combining copper, thermoplastics, and elastomers, and are tested for thermal shock and temperature cycling to ensure reliability.

PCB and Laminated Busbars

For high-power converters, PCB-based and laminated busbars are used to connect high-current and high-voltage subcomponents.

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B busbars reduce loop inductance, improve high-frequency current handling, and allow integration of components like sensors and capacitors. Laminated busbars are preferred in SiC high-power converters for their ability to handle high switching speeds and minimize parasitic effects.

Industrial and Data Center Busbars

Molex provides high-current, high-voltage busbar solutions for industrial and data center applications. These include side-exit receptacles, mezzanine board-to-board connectors, and wire-to-busbar interconnects. Features such as touch-safe designs, press-fit tails, and Coeur socket technology ensure low contact resistance, safety, and reliability in space-constrained environments.

Key Considerations

When selecting a high-voltage busbar model, consider: Voltage and current rating: Ensure the busbar can handle the system's electrical load. Insulation and safety: Overmolded or BBIT-insulated busbars provide protection against accidental contact. Application environment: Automotive, rail, industrial, or data center applications may require specific materials and thermal performance.

Form factor: PCB, laminated, or overmolded designs optimize space and reduce parasitic effects in high-frequency systems. Manufacturing and assembly: Automated production and multi-stage processes improve consistency and reliability. These models cover a wide range of high-voltage applications, from electric vehicles and locomotives to industrial power distribution and high-power converters, providing safe, efficient, and reliable power conduction.