Product novelty 22. September 2026
Reliable power transmission even in tight spaces
Shorter charging times for electric vehicles require higher charging power and voltages of 800 V and above. At the same time, thermal requirements for busbar insulation are increasing. EMS-GRIVORY has developed high-performance polyamides that provide reliable insulation properties even at high temperatures while reducing weight and costs.
Busbars are solid copper or aluminium conductors. They transmit high electrical power in confined spaces and connect the battery, inverter, DC-link systems and Power Distribution Units. Compared with conventional high-voltage cables, they enable compact, space-saving power transmission. At high charging power, busbars can briefly reach around 130 °C and, in extreme cases, up to 150 °C. Since the electrical insulation performance of many polymers decreases as temperature rises, the polymer insulation becomes a safety-critical factor, particularly in 800 V electrical systems. EMS-GRIVORY high-performance polyamides show a significantly lower decrease in volume resistivity even between 100 and 150 °C, ensuring reliable electrical insulation.
Modern high-voltage architectures typically use conductor cross-sections of 35 mm² to 120mm². As installation space is limited, busbars must be routed tightly around battery modules and power electronics components. Bending radii are often only one to two times the conductor thickness. Special EMS-GRIVORY high-performance polyamides provide high ductility and strong adhesion to copper and aluminium. This allows insulated busbars to be bent tightly without compromising the protective function of the insulation. Thin insulation layers and small bending radii reduce installation space, material use, weight and costs. The special grades are already in series production at European and Chinese automotive manufacturers. The patented EMS solution is designed for busbars at voltages up to 1,000 V.
Busbars are solid copper or aluminium conductors. They transmit high electrical power in confined spaces and connect the battery, inverter, DC-link systems and Power Distribution Units. Compared with conventional high-voltage cables, they enable compact, space-saving power transmission. At high charging power, busbars can briefly reach around 130 °C and, in extreme cases, up to 150 °C. Since the electrical insulation performance of many polymers decreases as temperature rises, the polymer insulation becomes a safety-critical factor, particularly in 800 V electrical systems. EMS-GRIVORY high-performance polyamides show a significantly lower decrease in volume resistivity even between 100 and 150 °C, ensuring reliable electrical insulation.
Modern high-voltage architectures typically use conductor cross-sections of 35 mm² to 120mm². As installation space is limited, busbars must be routed tightly around battery modules and power electronics components. Bending radii are often only one to two times the conductor thickness. Special EMS-GRIVORY high-performance polyamides provide high ductility and strong adhesion to copper and aluminium. This allows insulated busbars to be bent tightly without compromising the protective function of the insulation. Thin insulation layers and small bending radii reduce installation space, material use, weight and costs. The special grades are already in series production at European and Chinese automotive manufacturers. The patented EMS solution is designed for busbars at voltages up to 1,000 V.
EMS-CHEMIE AG
Contact
Ms. Jasmin Walt