The electrification, digitization and decentralized energy supply of our society keeps progressing at an increasing rate. Whether wind energy, photovoltaics or e-mobility: Effective components are needed that efficiently transport energy from producers to consumers. This is where busbars come into play: As "current bridges," they connect electric components particularly efficiently and make complex cable connections unnecessary. TB&C develops and produces custom busbars as hybrid components for your specific applications.
The design and series production of busbars for vehicles with electric or hybrid drives require a strictly controlled metal forming process, in-depth plastic overmolding expertise and highly qualified assembly processes. These are among the particular strengths of TB&C.
With many years of experience in the area of hybrid components for the automotive industry, we are the ideal partner for developing and producing your plastic-overmolded busbars. In the field of e-mobility or on other applications, such as in photovoltaics, to connect solar modules. You can always count on a parts quality that is second to none. The reliable basis for optimal performance, a long service life and top efficiency.
Our engineering team is constantly working on innovative ways to reduce weight, improve the heat management and simplify system integration. Our goal: To support your needs with efficient and future-proof high-voltage management solutions.
Battery Junction Box
Cell contacting system
Pouch cell frame
IGBT lead frame
Electric vehicles (EV) and hybrid vehicles (HEV) are now commonplace. The race of the car manufacturers has begun and yields tremendous potential. The goal is putting together the best package of comfort and performance at a competitive price.
The factor that determines the cost and performance of EV/HEV designs is the battery. Current electronic vehicles feature individual battery modules that are bundled into packages and connected via copper wires with the vehicle's electrical system. From there, once again using wires, the connection to the electric motor is made.
Busbars are the most efficient solution when it comes to these types of high-voltage connections. On behalf of a leading car manufacturer, TB&C is currently developing busbars with a copper insert that is overmolded with plastic. They offer significant technological and economic advantages compared to conventional cable connections:
lower impedance and a higher capacity in the areas of EMC, heat management and energy storage
and reduced material costs
through efficient use of materials
via plug connectors
through the faster replacement of battery packs
with regard to the shape and size of requirement-specific busbars
The replacement of conventional components with complete TB&C busbars has led to significant time savings at our production line and reduced the error rate in this area to a minimum. This made up for the higher development costs very quickly.