Laminated busbar: analysis of principles, applications and technical advantages

Power module laminated busbars are an electrical interconnection structure that is alternately stacked with multiple conductive layers and insulating layers and integrated into a whole through lamination or hot pressing processes. Its core advantage is to use the proximity effect to reduce the equivalent inductance of the loop: when the distance between the current-carrying layer and the return layer (the thickness of the insulation layer) is much smaller than the width of the busbar, the high-frequency current mainly flows on the inner plane of the adjacent conductor, and some of the alternating magnetic fields cancel each other out, thereby significantly reducing stray inductance. This feature is particularly critical for overvoltage spike suppression of high-speed switching devices such as IGBTs, which can reduce reliance on absorption capacitors and improve system electromagnetic compatibility.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

In terms of material selection, the conductive layer usually uses copper, brass or aluminum alloy with high conductivity; the insulating layer uses materials such as epoxy, polyester or aramid with high dielectric strength and excellent temperature resistance. In recent years, the application of copper-aluminum bimetal cold-rolling composite technology has achieved a balance between low cost, lightweight and high conductivity by compounding a copper layer on the surface of the aluminum substrate. At the same time, the introduction of new thermally conductive skeleton materials has further improved the heat dissipation capacity and high and low temperature resistance of Laminated Copper BusBar.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Compared with traditional cables or discrete busbars, Laminated Copper Bar has a number of technical advantages: Low impedance and low loss, optimized interlayer structure and short path design reduce resistance loss and voltage drop, improving energy transmission efficiency. Low stray inductance: Especially suitable for IGBT and high-frequency switching circuits, it can effectively suppress shutdown voltage spikes and reduce the risk of device damage. Excellent thermal management performance: The combination of multi-layer structure and thermally conductive insulating materials increases the heat dissipation area and controls the temperature rise at a low level. High reliability and safety: Interlayer insulation provides good electrical isolation, a sturdy structure, heat-resistant, wear-resistant, and vibration-resistant. Compact modular design: realizes high current and high voltage connections in a limited space, supports multi-interface customization, and is easy to install and maintain. These properties make Laminated Bus Bars for Power Electronics of significant engineering value in high-power-density systems.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With the above properties, laminated busbars have been widely used in many industries: Power electronics and energy systems: DC bus and capacitor bank connections such as high-power converters, UPS, wind and photovoltaic power generation systems, are used to reduce loop inductance and improve system stability. Transportation and new energy vehicles: In electric vehicles and rail transportation, Laminated Bus Bar for IGBT-based Motor Drive is used for battery pack interconnection and power conversion modules to support high current transmission and reliable operation. Information and communication equipment: including high-current power distribution inside communication base stations, large servers, switches and other equipment. Industrial and special equipment: applications in high-reliability environments such as high-frequency welding machines, military power systems, and IGBT Laminated Bus Bar for Spacecraft Power Inverter.

 

 

Relying on advanced lamination technology and material research and development capabilities, we are committed to providing customers with a full range of Laminated BusBar for Mersen solutions. If you are looking for high-quality components that can be perfectly adapted, please feel free to contact us and we will provide you with professional technical support and customized services.