Typically, these busbars have nylon-based insulation and only require a 125°C temperature rating. However, future requirements may require higher temperature ratings, and Aptiv is at the forefront of developing appropriate materials to meet these needs.
Engineers should consider the potential of a material that can withstand wear while maintaining much-needed flexibility and robust temperature ratings. While XLPO and silicone are similar in cost, XLPO is unlikely to require additional coverings—a cost avoided with fewer assembly steps, less labor, and less material. This innovation presents a unique opportunity as electric vehicles become more commonplace.