ENNOVI has introduced ENNOVI-SealTech, a new busbar sealing technology that addresses one of the persistent challenges in hybrid and electric vehicle drivetrain engineering. The solution is designed to prevent coolant leakage at critical interconnects and can be applied to both busbars and other connection points found in motors, inverters, and oil pump interfaces.

In modern electric vehicle architectures, the interface between liquid-cooled and electrically isolated regions is a well-known point of vulnerability. Traditional sealing methods, including potting, rubber O-rings, and gaskets, often require additional manufacturing steps and increase costs. Over time, these methods can suffer from leakage or degradation, especially when exposed to the demanding thermal and mechanical loads typical in automotive environments.

ENNOVI-SealTech addresses these issues by offering two alternative sealing strategies. Engineers can select either double-walled shrink tubes or adhesive tape, both of which conform tightly to a variety of busbar geometries. This approach removes the need for post-processing and secondary operations, streamlining assembly and providing greater design flexibility. As a result, custom busbar shapes can be specified without being limited by the constraints of traditional sealing hardware.

The reliability of this technology is supported by a comprehensive validation program. Each configuration undergoes thermal aging at high temperatures for extended periods, as well as repeated thermal shock cycles that simulate real-world automotive conditions. Dedicated pressure testing is also carried out to confirm that the seal maintains its performance throughout the expected service life of the vehicle.

Material compatibility is another key advantage. ENNOVI-SealTech works with a wide range of metals and polymers commonly used in automotive power electronics, such as copper, aluminum, PA66, PBT, and PC. This broad compatibility makes it a practical choice for manufacturers looking to standardize sealing solutions across multiple platforms and applications.

By removing secondary sealing processes and enabling more flexible busbar designs, ENNOVI-SealTech offers a more efficient and reliable approach compared to legacy methods. This new technology supports the evolving requirements of next-generation electrified drivetrains, delivering improvements in both manufacturing efficiency and long-term performance.

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