Highly efficient battery systems are the key to success of electromobility as the power is transmitted from the charging components to the battery and from there to the electric motor. This is done by metal busbars. Plastic overmoldings ensure electrical insulation of the busbars and, thus, safe distribution of the high-voltage currents.

BASF is expanding its portfolio with a newly developed thermoplastic polyurethane (TPU) from its Elastollan product line for these busbar holders. Compared to standard engineering plastics, Elastollan R 2600 FHF stands out due to the optimized thermal linear expansion.

Its linear thermal expansion coefficient is close to copper and comparable conductor materials. This reduces the risk of cracks occurring during temperature changes which increases the safety standard. Furthermore, Elastollan is a halogen-free flame retardant achieving the classification UL94 V-0.

In addition to the main aspect of thermal linear expansion, the TPU also has three advantages compared to materials such as polyphenylene sulfide (PPS), according to BASF: it can be processed at lower temperatures; it has a lower density; and, due to its white color, can be easily colored even with bright pigments.

Busbar holders made of Elastollan R 2600 FHF

Moreover, BASF is able to simulate the design of busbar holders.