Laminated Busbar: A Key Component In New Energy Hardware Material Solutions

 

Structural Composition

 

The laminated busbar is mainly composed of conductive layers and insulating layers alternately superimposed. The conductive layer usually uses highly conductive metal materials. In new energy applications, copper is a common choice. Copper has extremely low resistivity and can conduct electrical current efficiently. The insulation layer uses high-performance insulation materials, such as polyester film (PET) or polyimide film (PI). These insulating materials have excellent electrical insulation properties, good mechanical strength and heat resistance, effectively isolating each conductive layer and preventing abnormal conduction of current between different layers.

 

Working Principle

 

Its special multi-layer structure design gives the laminated busbar unique performance advantages during current transmission. When current passes through the laminated busbar, the magnetic fields generated by the current interact due to the close arrangement and reasonable layout between the conductive layers. In the case of high-frequency current transmission, this structure can significantly reduce the inductance value. Low inductance characteristics are very critical in new energy equipment, such as in inverters, which can reduce voltage spikes during switching and effectively suppress electromagnetic interference (EMI), thus improving the stability and reliability of the entire equipment.

 

 

 

High Conductivity And Low Resistance

 

In new energy equipment, it is often necessary to transmit large currents. The conductive layer of the laminated busbar is made of high-quality metal materials to ensure high conductivity. Its low resistance characteristics can reduce the loss of electrical energy during transmission and improve energy utilization efficiency. For example, in the battery management system of electric vehicles, the laminated busbar can effectively transmit the power of the battery pack to each power consumption unit, reduce the heat generated by resistance, extend the battery life and improve the vehicle's endurance.

 

Compact Design And Space Saving

 

New energy equipment often has strict space requirements. The multi-layer structure of laminated busbars allows the integration of multiple circuits into a compact component. Compared with traditional cable and busbar connections, it takes up significantly less space. Taking new energy charging piles as an example, the application of laminated busbars can make the internal structure of the charging pile more compact, facilitate installation and layout, and also help realize the miniaturization design of the charging pile.

 

Good Heat Dissipation Performance

 

Since power transmission in new energy equipment is usually accompanied by the generation of heat, heat dissipation performance becomes an important consideration. The metal conductive layer of the laminated busbar has good thermal conductivity, and the insulating layer also contributes to the diffusion of heat to a certain extent. Moreover, the design can optimize the heat dissipation structure, such as adding heat dissipation fins or using insulating materials with better heat dissipation performance, to ensure that the laminated busbar can quickly dissipate heat during high-load operation, maintain a stable operating temperature, and improve Equipment reliability and service life.

 

 

 

Production Process

 

In the production workshop of ASWT, the production of laminated busbars is a rigorous and precise process. We have a professional technical team who carefully select each raw material and conduct strict raw material inspection on conductive materials and insulating materials to ensure that their quality meets high standards. Then, advanced cutting equipment, such as a laser cutting machine, is used to precisely cut the conductive and insulating layers to the required size and shape. Next, the conductive layer and the insulating layer are alternately stacked through a lamination process and pressed under specific temperature, pressure and time conditions to ensure a tight bond between the layers. Finally, surface treatment, cleaning and other processes are carried out to achieve the best performance of the laminated busbar.

 

Quality Control

 

Quality control runs through every aspect of laminated busbar production. At ASWT, we have established a complete quality inspection system. During the raw material inspection stage, parameters such as the purity and hardness of conductive materials and the insulation performance and thickness of insulating materials are strictly tested. During the production process, cutting accuracy, lamination bonding strength, surface flatness, etc. are monitored in real time. In the finished product stage, comprehensive electrical performance tests are carried out, including withstand voltage tests, insulation resistance tests, continuity tests, etc., and the appearance is carefully inspected to ensure that the laminated busbars have no scratches, deformations and other defects. Only those that pass all quality inspections products will be allowed to enter the market.

 

 

 

Application cases

 

In solar photovoltaic power generation systems, laminated busbars are used to connect photovoltaic cell arrays and inverters. It can transmit DC power efficiently and maintain stable performance in complex outdoor environments. In wind power generation equipment, laminated busbars are also widely used for power transmission and control system connections in the cabin, ensuring stable power generation and power transmission of wind turbines at different wind speeds. These successful application cases all benefit from ASWT's strict control over the quality and performance of laminated busbars.

 

Market Prospects

 

As the global demand for new energy continues to grow, the market size of new energy equipment is also expanding rapidly. As a key hardware material in new energy equipment, laminated busbar has a very broad market prospect. With the continued development of the electric vehicle industry and the increasing popularity of solar and wind power generation, the demand for laminated busbars will continue to increase. ASWT focuses on the production and export of laminated busbars. With advanced production technology and strict quality control, it will play an important role in this growing market and provide high-quality hardware for the development of the global new energy industry. Material Solutions.

 

 

 

Since 2010, Xiamen Apollo Stamping Welding Technology Co., LTD has specialized in Metal Stamping and Welding solutions for New Energy, like Fuse Copper Contact Cap, Battery Aluminum Case and Safety Cover, EV Film Capacitor Copper BusBar, Laminated Copper BusBar, Insulated Copper Busbar, Flexible Busbar, and other electrical products Metal Stamping and Welding Assembly. Our teams are the experts from their respective fields, we can not only provide customers with products of qualified quality and competitive price, but also offer technical solutions to reduce costs but increase efficiency.