Advanced functionality with innovative busbar sealing technology for EV and hybrid drivetrains

ENNOVI introduces a new technology for sealing busbars, which prevents coolant leakage in hybrid and electric vehicle (xEV) drivetrain applications. ENNOVI-SealTech can be employed with either busbars or other interconnects to accommodate applications such as motors, inverters or oil pump interfaces.

“Managing busbar interfaces in EVs where coolant is present on one side and a dry, electrically robust connection is required on the other side, presents several challenges,” explains Dominik Pawlik, product portfolio director for Power Interconnects at ENNOVI. “Conventional sealing methods, such as potting or using rubber O-rings or gaskets, incur the high cost and time for secondary processes and/or issues with leakage over the lifetime of the assembly – ENNOVI-SealTech overcomes all these limitations.”

The technology offers two sealing methods: double-walled shrink tubes or adhesive tape for challenging applications. Both eradicate post-processing, improving manufacturing efficiency and design flexibility without sacrificing sealing performance.

This technology is subjected to rigorous testing to ensure it fulfils the specific needs of each design. Every configuration is validated through a comprehensive testing process, including thermal ageing at 150C for 1,000 hours, and thermal shock cycling from -40C to +150C for 600 cycles (15 minutes per cycle), in accordance with the EN 60068-2 standard. A leak test is also performed to verify sealing integrity.

The use of shrink tubing or tape permits ENNOVI-SealTech to adapt to virtually any busbar shape and design specification. Moreover, the technology is compatible with a wide range of metals and plastics, including copper (Cu), aluminium (Al), PA66, PBT, PC, and others.