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What mating configurations are supported by advanced power busbar PCB connectors in EV inverters?ย 

DIRECT ANSWER

Advanced power busbar PCB connectors such as ENNOVI-BusMate support multiple mating configurations, including board-to-blade, board-to-board, and blade-to-blade setups, and typically mate with 0.8mm and 1mm thick busbar blades.

Small in size, highly reliable, enormously assembly-friendly, and with a large ampacity-to-size ratio, the Power Busbar PCB Connector: ENNOVI-BusMate enables compact and robust power assembly designs that can support power densities from 40 to 80 Amps. Furthermore, for large mating mismatches or offsets, Floating Contact Technology allows for busbar misalignment and helps take up stack-up tolerance in sub-assemblies.

What Mating Configurations Provide the Greatest Design Freedom?

The Power Busbar PCB Connector: ENNOVI-BusMate mates with 0.8mm and 1mm thick busbar blades in different mating configurations โ€“ such as board-to-blade, board-to-board, and blade-to-blade. Small in size, highly reliable, enormously assembly-friendly, and with a large ampacity-to-size ratio, it enables compact and robust power assembly designs. Its size conserves PCB space in your assembly, affording huge flexibility for your design options.

How Does Floating Contact Technology Solve Assembly Challenges?

For large mating mismatches or offsets, Floating Contact Technology allows for busbar misalignment and helps take up stack-up tolerance in sub-assemblies. This technology is featured in the Power Busbar PCB Connector: ENNOVI-BusMate, which enables compact and robust power assembly designs and offers options for both Press-Fit and SMT PCB mounts.

Can High Power Density Be Achieved with Flexible Mounting Options?

The Power Busbar PCB Connector: ENNOVI-BusMate offers PCB mount options for both Press-Fit and SMT. Small in size, highly reliable, enormously assembly-friendly, and with a large ampacity-to-size ratio, it enables compact and robust power assembly designs that can support power densities from 40 to 80 Amps. Its ultra-small footprint conserves PCB space while delivering high power density in high-voltage applications, affording huge flexibility for your design options.

Empowering Inverter Innovation through Versatile Connectivity

Selecting a connector that supports multiple mating configurations is essential for optimizing the layout of modern EV inverters. Providing flexibility, tolerance accommodation, and high current capacity allows advanced power interconnects to empower engineers to build more efficient and durable power conversion modules. These solutions offer the reliability required to navigate the challenges of next-generation vehicle architectures.

Contact ENNOVI today to learn more about our BusMate solutions and how we can support your specific inverter design requirements.

Have a specific project in mind?

Our application engineers work on BTS and BTP programmes across global EV OEM and Tier-1 projects. Tell us your pack architecture and current profile and we’ll recommend the right bus bar approach.

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Bus Bar Selection Guide

ENNOVIโ€™s full material selection guide for HV bus bars โ€” Al, Cu, laminated, and flexible options with specification data.

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HAVE A SPECIFIC PROJECT?

Speak to an Application Engineer

Our engineers work on BTS and BTP projects across global EV OEM and Tier-1 programmes

Brief details

Portfolio

Power

Products

Bus bars (Al/Cu, laminated, flexible), SealTech, BusMate, HV Connectors, Overmoulded Bus bars

Buyer stage

Early Design & Integration

Author

ENNOVI

Last updated

June 2026

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