Busbar Protection

Oerlikon’s TX200 advanced busbar protection system prevents dangerous arcing throughout the entire battery system. Combining high-temperature resistance with outstanding electrical insulation, it delivers reliable protection even under extreme conditions and sets new benchmarks for next‑generation battery designs.

In EV battery packs, busbars serve as critical current carriers connecting cells, modules, and other high‑voltage components. In the event of a thermal runaway, unprotected busbars may come into contact with hot, electrically charged gases – a situation that can cause short circuits, severe arcing, or complete system failure. TX200 effectively insulates these conductors, safeguarding the high‑voltage system and mitigating cascading cell reactions. This prevents secondary damage to the battery, the vehicle, and its occupants.

At just 0.8 mm thickness, TX200 is exceptionally lightweight. Its flexible, non‑brittle structure enables simple integration into compact battery architectures without compromising performance. With proven resistance up to 1000 °C and a breakdown voltage of 10 kV DC, TX200 meets the requirements of IEC 61439‑1 and holds a UL94 V0 flammability classification. The material ensures stable and safe operation across all modern battery platforms.