A Review of Research on the Industrial and Technological Development of Laminated Busbars

As a critical conductive interconnect structure in power electronics systems, the laminated busbar is essentially a low-inductance, high-reliability electrical connection solution formed by laminating alternating layers of conductors and insulating media. Typically constructed from copper or aluminum conductors interleaved with insulating materials such as PET or epoxy, it offers significant advantages under high-frequency and high-current operating conditions. As power electronics systems evolve toward higher power densities, laminated busbars have increasingly become core components in drive systems.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In new energy vehicles and industrial electric drive systems, laminated busbars are primarily used to optimize current paths, reduce parasitic inductance, and enhance system switching performance; their design directly impacts inverter efficiency and reliability.

 

Particularly in IGBT applications, these busbars effectively suppress voltage spikes and electromagnetic interference through structural optimization, serving as a vital component of high-performance drive systems.

 

In energy storage and renewable energy converter systems, the laminated structure serves not only a conductive function but also requires highly integrated designs with capacitor systems. Laminated busbars are frequently employed to establish low-impedance connections between capacitors and power modules, thereby improving system transient response and overall energy efficiency.

 

In the field of high-power industrial variable-frequency drives, where requirements for current-carrying capacity and thermal stability are constantly rising, laminated busbars have become a standard structural solution for high-power inverters, playing a crucial role in minimizing losses and enhancing heat dissipation.

 

With the increasing integration of power semiconductor packaging, busbar structures at the circuit board level are also being introduced into high-density power system designs. Through collaborative design with PCB systems, these busbars achieve an optimized balance between high integration and low parasitic parameters.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In aerospace and specialized power supply sectors, where systems demand extreme lightweighting and high reliability, laminated busbar structures meet the needs of harsh operating environments through optimized materials and manufacturing processes. They serve as key interconnect solutions for high-reliability aerospace power inverters.

 

In energy storage and DC bus systems, busbar structures are commonly used to integrate mechanical support and electrical connections for capacitor arrays. Laminated busbars for capacitor bank mounting structures reduce system volume and enhance electrical consistency through structural integration.

 

In the field of high-frequency industrial power supplies-particularly in induction heating and welding power systems-requirements for minimizing high-frequency losses and ensuring electromagnetic compatibility are extremely stringent. Laminated busbars designed for high-frequency welding power IGBTs significantly reduce losses along high-frequency current paths by optimizing the interlayer structure.

 

High current capacity and high reliability are core design requirements for rail transit traction systems. Busbars for electric locomotives are widely used in traction converters and auxiliary power systems to ensure stable power distribution and transmission.

 

From the perspective of overall power electronics system architecture, busbars serve not merely as connecting components but as vital elements in optimizing the system's energy path. Busbars for power electronics play a key role in increasing system power density and minimizing parasitic parameters.

 

Insulated protection structures are becoming a standard design requirement in medium- and low-voltage power distribution and industrial control systems. Varnished Insulated Busbars (VIB) enhance safety and environmental resilience through an insulating coating, making them suitable for complex industrial environments.

 

Within power distribution networks, busbar systems perform the critical functions of backbone current transmission and branch circuit control. Busbar solutions for electrical power distribution utilize modular designs to achieve efficient power distribution and system scalability.

 

As structured conductive components, laminated busbars are designed to strike a balance between low inductance and high reliability. They have become a standard electrical connection solution in new energy and industrial systems.

 

In system-level power integration, busbars must do more than conduct electricity; they must be optimized in coordination with the overall power architecture. Integrated busbar solutions for power electronics exemplify the trend of evolving from individual components to system-level solutions.

 

In electrical protection systems, busbar structures must be tightly integrated with protective devices to improve system response speed and safety. Busbars customized for electrical protection solutions are typically tailored to specific application scenarios.

 

In alternative energy systems, conductive busbars are essential for energy transmission and system interconnection. Copper busbars for alternative energy applications are widely used in photovoltaic and energy storage systems due to their excellent electrical conductivity.

 

At the structural design level, the performance of laminated busbars relies heavily on design methodologies that optimize across multiple physical domains. Laminated busbar designs achieve optimal system performance through coupled electromagnetic, thermal, and mechanical analysis.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In industrial automation and general electrical equipment, busbar structures must balance cost and reliability. Laminated busbars for industrial applications are widely used in various industrial drives and control systems.

 

High-density power distribution is a key technological focus in computer and high-performance power supply systems. Laminated busbars for computers enable efficient power management and low-noise transmission through compact structural designs.

 

Busbar structures handle high-frequency, high-current transmission in dynamic reactive power compensation and high-voltage power quality management systems. Busbars for high-voltage SVG (Static Var Generator) systems play a vital role in grid stability regulation.

 

Busbar structures directly impact system efficiency and reliability in photovoltaic (PV) inverter systems. Laminated busbars for PV inverters enhance the conversion efficiency of PV power generation systems through low-inductance designs.

 

In DC bus and power capacitor systems, busbar structures require extremely low impedance and high transient load-bearing capabilities. Laminated busbars for power capacitor DC links are widely used in high-performance power electronics conversion systems.