HPW offers solutions for all variants of electric mobility from PHEV, HEV, to BEV and FCEV. Performance wires from HPW are an essential component of a stator in electric vehicles of the latest generation. With the electrical energy provided from the battery or fuel cell, the stator generates a magnetic field and drives the rotor in the electric motor.
The customized high-tech product winding wire is insulated with polyamideimide (PAI) or polyetheretherketone (PEEK). When selecting the insulation system, system voltage, motor type, vehicle type (passenger car, truck, bus) and the required life time (up to 50,000 hours) are decisive.
With worldwide state-of-the-art machines as well as stable production and monitoring processes for enameled flat wires, HPW supplies well-known OEM's and Tier 1 suppliers. HPW thus ensures security of supply in a dynamically growing industry.
HPW's particularly low-defect and multi-layer insulated flat wires increase the efficiency and thus the effectiveness of electric drive trains.
Increasing demands on electric motors require particularly good use of the available installation space, which is why winding wires with rectangular cross-sections are increasingly being used instead of insulated round wires.
HPW's high level of innovation is demonstrated by several patented, exclusive manufacturing processes using high-performance polymers such as PEEK. These extrusion processes make it possible to apply polymer-based insulation systems with firm adhesion directly to the wire surface.
A loadable temperature range of up to 260° Celsius, the flexibility in the bending process and the better electrical insulation properties (dielectric strength) of the material clearly surpass those of enamel (PAI).
In particular, the increasing system voltage levels (up to 1000 volts) and the resulting operating temperatures in the electric motor lead to ever higher thermal loads.
Efficient and low-loss distribution of charging energy in the battery system is becoming increasingly important as a result of increasing charging powers. For this reason, HPW produces dimensionally stable flat conductors, so-called "rigid busbars", which withstand the high demands of the tightest bending radii and high electrical and mechanical stress.
HPW manufactures customer-specific conductor cross-sections up to 400 mm² in an automated process that covers the entire value chain from the primary material made of copper or aluminum to the finished, insulated flat conductor. Increasing requirements such as weight reduction, bending radii and temperature resistance of the insulation (e.g. thermal runaway) are transferred to series production with the help of international research projects.
High Performance Busbars is a joint venture between HPW and the German company BRAND KG (brandgroup). High Performance Busbars combines expertise in innovative high-tech flat conductors and customized busbars for the e-mobility industry under one roof — from material development to complete system solutions. Sales are managed through its global locations close to customers. High Performance Busbars brings together technological expertise and manufacturing know-how for energy distribution in the high-voltage systems of battery-electric vehicles.
