Popularization of professional knowledge in the laminated busbar industry

Laminated busbar, also known as composite busbar or composite copper busbar. It is an integrated composite structure connecting row formed by alternately laminating multiple layers of conductive materials (such as copper, aluminum) and insulating materials (such as epoxy resin, polyester, aramid, etc.) through lamination or hot pressing technology. This structural component can be regarded as a highway of the power distribution system, providing a low-impedance, high-efficiency energy transmission channel for high-current, high-voltage electrical systems. Compared to traditional, bulky, time-consuming and cumbersome cabling methods, laminated busbars offer a modern, easy-to-design, quick-to-install and clearly structured power distribution solution. It has the characteristics of repeatable electrical performance, low impedance, strong anti-interference ability, good reliability, space saving, simple and fast assembly, etc. It is a high-power modular connection structure component. In power electronics systems, Bus Bar for Power Electronics Bunding Solutions is based on this design concept, integrating complex power connection paths into compact, standardized busbar components, thereby significantly improving system integration and manufacturability.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Laminated busbars can be divided into various structural types according to their edge treatment methods and packaging forms to meet the requirements of different application scenarios for insulation protection level, environmental resistance, and cost control. The first type is the resin potting type, which means that the laminated conductor and insulation layer are integrally potted in special resin to form a completely sealed component. It has the highest insulation protection level and resistance to moisture, salt spray, and pollution. It is suitable for outdoor or harsh industrial environments. The second type is the open-edge type, that is, the edges of the laminated busbar are not additionally sealed and the insulation layer is directly exposed to the air. This structure is simple to manufacture and low-cost, and is suitable for dry and clean indoor environments. The third type is the edge-sealing type, which uses insulating materials to seal the edges of the laminated busbar to prevent the edges of the conductive layer from being exposed, thus improving the creepage distance and voltage withstand capability. It is the most common structural form in industrial frequency converters and inverters. The fourth category is the resin spray edge sealing type, which means that on the basis of edge sealing, the outer surface of the busbar is powder sprayed or resin sprayed to further enhance the insulation and anti-corrosion properties.

 

In terms of manufacturing process, the production of laminated busbars involves conductive layer cutting, deburring, chamfering, surface treatment (such as tin plating, silver plating or passivation), insulating film cutting and stacking, hot press forming, edge milling and edge sealing, voltage withstand testing and dimensional inspection. The hot pressing process is a key process. It needs to be under appropriate temperature, pressure and time conditions to make the insulating material fully flow and firmly bond to the surface of the conductive layer, and at the same time discharge the remaining air between the layers to ensure no bubbles and no delamination. Laminated Bus Bar Design At this stage, factors such as the thickness and width ratio of the conductive layer, the material and thickness selection of the insulating layer, hot pressing parameters, and subsequent processing allowances need to be fully considered to balance electrical performance, mechanical strength, and manufacturing costs. For Laminated Bus Bar for Industrial applications, it is often necessary to add additional heat dissipation structures or temperature monitoring components to the design to meet the reliability requirements of long-term continuous operation in industrial environments.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

As an innovative electrical connection method, laminated busbar has been widely and deeply used in many industrial fields due to its excellent electrical performance, heat dissipation performance, compact structure and high reliability. In the field of power electronics and energy, laminated busbars are widely used in high-power converter systems, including solar inverters, wind power converters, energy storage converters and uninterruptible power supply systems. In these devices, the laminated busbar is mainly responsible for connecting IGBT or silicon carbide power modules and DC bus capacitors. By greatly reducing the stray inductance of the commutation circuit, it effectively suppresses the voltage spike during the switching process of the power device, thereby reducing the number of absorption capacitors used, reducing system costs, and improving electromagnetic compatibility performance.

 

In the field of transportation, laminated busbars are widely used in rail transit traction converters, auxiliary power systems, and battery pack connections, motor controllers and high-voltage power distribution units of new energy vehicles. Especially in the electric vehicle industry, strong market growth has become an important new driving force for the expansion of the laminated busbar market. In the field of information and communications, laminated busbars are used in cellular communication base stations, large-scale network equipment, telephone switching systems, and power distribution systems of large and medium-sized computers. Its low impedance and good heat dissipation performance can ensure long-term stable operation of communication equipment under high loads. In industrial and special fields, laminated busbars are used in welding systems, military equipment systems, power generation systems, and power conversion modules for electric equipment.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

From the perspective of technology development trends, laminated busbars are evolving towards higher integration, lower inductance, better heat dissipation, and more intelligence. On the one hand, integrating temperature sensors, current detection components and even some passive filter components into the busbar to form intelligent power connection components is one of the current research hotspots. On the other hand, with the popularization and application of wide bandgap power devices such as silicon carbide and gallium nitride, the switching frequency has increased from tens of kHz to hundreds of kHz, which has put forward lower requirements for the stray inductance of laminated busbars and promoted the development of busbar structures toward thinner insulation layers, more precise laminations, and three-dimensional shaping. At the same time, the application of new materials is also constantly expanding the performance boundaries of laminated busbars, such as the use of high thermal conductivity insulation materials, ceramic filled composite materials, and copper-aluminum composite conductive layers. These technological advances will further consolidate the core position of laminated busbars in high-power power electronic systems.

 

 

If you are looking for a highly reliable Laminated Low Inductive Bus Bar, please contact our engineering and technical team. We will provide you with professional product selection support and one-stop supporting services.