Thermal management mechanism and engineering application of high-power Intelligent laminated busbar
Mar 13, 2026
Heating mechanism and structural countermeasures
The Joule heating (Q=I ² Rt) and distributed inductance losses in power transmission are the main reasons for the decrease in system efficiency. Intelligent laminated busbars solve thermal problems from the root by using a laminated structure of alternating layers of conductive foils and insulating materials. Traditional circular cables have reduced effective conductive areas due to limited cross-sectional area and significant skin effect; The multi-layer parallel design of the stacked busbar significantly increases the equivalent cross-sectional area and reduces the DC resistance.
The single-layer thickness is controlled within the skin depth to evenly distribute high-frequency current and avoid surface overheating. The tightly laminated structure of the Laminated copper busbar cancels out the magnetic fields of the positive and negative polarity layers, reducing the distributed inductance to less than 1/10 of the traditional scheme. This low inductance characteristic reduces reactive power losses and switch surges, suppressing additional heating from the source.
Optimization design of heat dissipation path
The flat structure of the Intelligent laminated busbar has an excellent surface area/volume ratio, making it easy to directly attach to heat dissipation substrates or liquid cooling systems. Taking the inverter of new energy vehicles as an example, after the laminated busbar is bonded to the water-cooled plate, the working temperature can be controlled within 60 ℃, which is more than 30 ℃ lower than traditional cables.
The selection of insulation materials simultaneously affects thermal resistance and heat dissipation efficiency. Polyimide film can withstand high temperatures up to 180 ℃, while epoxy resin coating provides mechanical protection and additional heat dissipation channels. The Laminated flexible busbar achieves rapid heat dissipation and dissipation through a synergistic system of "conduction insulation heat dissipation".
Typical application scenario verification
In the power battery system of new energy vehicles with hundreds of kilowatts, the efficiency of the power system is improved by 2% -3% after replacing cables with Laminated inverter busbars. The low resistance characteristics of laminated busbars reduce Joule heating generation, extending the lifespan of components by more than 15%.
The low inductance characteristics of the stacked busbar in the battery module convergence and power conversion process of the energy storage power station reduce PCS switch losses. At the same time, to avoid the risk of insulation aging caused by thermal accumulation at the junction point, Laminated copper bars have become a key connection solution for high-power DC systems.
In the connection scenario of industrial frequency converter power modules, the multi-layer structure of the stacked busbar effectively suppresses the high-frequency skin effect. By reducing the operating temperature of the module by 10 ℃ -20 ℃, the stacked bus significantly improves the long-term reliability of power semiconductors.
Key process control points
The implementation of performance depends on the precise coordination of materials and processes. The conductive layer of the Laminated bus bar for telecom is made of high-purity oxygen free copper or 1060 aluminum alloy to ensure intrinsic low resistance. The vacuum hot pressing process eliminates interlayer bubbles, prevents partial discharge and increases thermal resistance, which is the core link of quality control for laminated busbars.
Inter layer alignment accuracy control avoids local overheating caused by uneven current paths. During the design phase, it is necessary to optimize the number of layers and single-layer thickness of the Laminated bus bar for high current inverter based on the current carrying capacity and frequency characteristics. The customized outline of the laminated busbar needs to balance thermal, electrical, and mechanical properties to meet specific spatial constraints.
Contact us
If you need to optimize the thermal design scheme of Intelligent laminated busbar for your specific application scenario, or obtain customized technical specifications and sample support, please feel free to contact our engineering team for detailed solutions.
