EV busbars: Eliminate hotspots with self-aligning, quick-connecting continuous material

Sponsored by Eaton

Royal Power Solutions, established in 1938 and acquired by Eaton earlier this year, is a global leader in the development and production of critical high-precision power- and signal-distribution components.

Royal Power Solutions is recognized for its numerous industry-leading electrical components and capabilities, including RigiFlex^™ flexible busbars, high-power lock box (HPLB) terminal connectors and its state-of-the-art stamping facility. Demand for these innovative components is rapidly increasing among global electrified vehicle manufacturers. 

Traditional busbars contain multiple hotspots due to numerous welds and dissimilar materials. We’ve overcome these shortcomings with our RigiFlex^™ busbar by creating one continuous length of material that is both rigid and flexible as required within the application environment. 

The RigiFlex flexible busbars can be manufactured in copper or aluminum. Eaton’s unique, simple, 1-piece flow for manufacturing, has the ability to scale to any customer volume needed. By combining our HPLB terminal system and RigiFlex^™ flexible busbars we can create a self-aligning, quick connect solution that reduces our packaging envelope and are 100% insulated.

The RigiFlex busbars allow vehicle manufacturers to eliminate fasteners in their components and to experience a decrease in warranty issues related to torque joint failure as well as the ability to automate the installation of the busbar to a battery pack. RigiFlex^™ busbars are supplied to the automotive, electrified vehicle, truck, bus and off-roading markets.

Eaton’s specialized HPLB power connectors are for current and future electrified vehicle solutions. The HPLB connectors offer a space-saving profile, superior performance, cost savings and reduced manufacturing complexity. The HPLB terminals provide efficiency and reliability as well as protection against the elements. Additionally, the HPLB terminals are waterproof up to 1 meter deep and strong enough to withstand high-pressure water spray.

The HPLB terminals are a “plug-in” solution with a smaller footprint, resulting in less weight and a reduced profile. Eaton uses a progressive stamping process to manufacture the HPLBs compared to the more costly complex billet machining, stamping and forming process competitive products require.

Eaton’s HPLB terminal system forms a connection in a unique way that provides improved contact force as the temperature increases. Unlike traditional male-to-female terminal connections, Eaton’s HPLB Terminals use an inverted contact system. This unique configuration provides a stronger connection than that of conventional box-and-blade connectors where the female terminal spring squeezes the male blade, which loosens when exposed to heat and vibration, resulting in a loss of power flow continuity and the possibility of corrosion

Eaton’s stamping facility includes high-speed Bruderer, Minster and Aida Punch presses starting at 30 tons. The process is focuses on a collaborative, customer-centric strategy for optimum results, delivering quality and reliability. These methods allow for scalable growth with vehicle manufacturers as their product lines expand.

Royal Power Solutions components are now designed and incorporated into Eaton’s eMobility products, such as DC-DC converters, battery-disconnect and power-distribution units. With the integration of Royal Power Solutions, Eaton’s components are now vertically sourced, reducing complexity and time to market, as well as optimizing system performance.

Sponsored by Eaton