Ems-Grivory: High-Performance Polyamides for Busbar Insulation in Electric Vehicles

Patented EMS solution for busbars operating at voltages of up to 1,000 V – (Photo: Ems-Grivory).

The Ems-Grivory business unit of Ems-Chemie AG has developed high-performance polyamides for the plastic insulation of busbars in electric vehicles. The materials are designed for high-voltage systems with increasing requirements for dielectric strength, temperature resistance and efficient use of installation space. According to the company, the patented busbar solution is designed for voltages of up to 1,000 V. The company is presenting the development at Fakuma 2026.

Electrical Insulation at Temperatures of up to 150°C
Busbars are made of copper or aluminum and connect components such as batteries, inverters, DC link systems and power distribution units. As the industry transitions from 400 V to 800 V architectures and higher charging capacities, the requirements for electrical insulation are increasing. Under short-term loads, busbar temperatures can reach around 130°C and, in extreme cases, up to 150°C.

Advert

Since the volume resistivity of many plastics decreases as temperatures rise, the thermal stability of the insulating layer is particularly important. According to the manufacturer, the polyamides developed by Ems-Grivory exhibit a comparatively small reduction in volume resistivity at temperatures between 100°C and 150°C.

Thin Insulation Layers and Tight Bending Radii
Typical conductor cross-sections in high-voltage systems range from 35 to 120 mm². The metal conductors are coated with plastic using an extrusion process, cut to length and then bent into their final shape. Bending radii are often only one to two times the conductor thickness. The insulation must neither crack nor become excessively thin on the outside of the bend, while wrinkling must be prevented on the inside.

According to Ems-Grivory, the specialty polyamides are designed to provide high ductility and strong adhesion to copper or aluminum. This is intended to enable tight bends after insulation has been applied, as well as thinner insulation layers. As a result, installation space requirements, material consumption and component weight can be reduced. However, the company does not provide specific comparative figures for insulation thickness, weight savings or costs.

Series Production Applications in Europe and China
According to Ems-Grivory, the corresponding polyamide grades are already being used in series production by European and Chinese automotive manufacturers.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall B2, Stand 2113

More information: www.ems-group.com, www.emsgrivory.com

Ems-Chemie AG, Ems-Grivory, Herrliberg and Domat/Ems, Switzerland

back to news list