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About A&J
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
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Products&Service
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
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Solutions
A&J Link Technology Co., Ltd. traces its roots back to Suzhou Aierjie New Material Technology Co., Ltd., which was founded in 2017. Since its establishment, it has been dedicated to the research and development, design, production and manufacturing of PP, PC insulating sheets and busbars.
Integrated capacitor busbar
Product Details
Integrated Capacitor Busbar: The Complete DC-Link Solution
At A&J LINK, we combine decades of expertise in laminated busbar design with advanced capacitor integration, delivering a complete, high-performance DC-Link solution. Our Integrated Capacitor Busbars (ICBs) or "Busbar Capacitor Assemblies" are engineered to maximize the performance, reliability, and power density of modern power electronics systems.
Integrated Capacitor Busbar Specifications & Technical Parameters
Typical Operating Parameters:
- Rated Voltage: 400V ~ 1100V DC
- Capacitance Range: 80μF ~ 1000μF
- Operating Temperature: -40°C ~ 105°C
- Heat & Humidity Resistance: 85°C / 85% RH
- Current Carrying Capacity: Up to ~650A
- Size & Configuration: Fully Customized Design
What is an Integrated Capacitor Busbar? Definition & How It Works
An Integrated Capacitor Busbar is a sophisticated subsystem that seamlessly combines a high-performance laminated busbar with DC-Link filter capacitors into a single, compact, and optimized assembly. It transforms the traditional, discrete connection of separate capacitors and busbars into a unified, low-inductance power loop structure. This solves critical electrical challenges at the system level, rather than just the component level.
Benefits of Integrated Capacitor Busbars vs Discrete Components
Dramatically Reduced Loop Inductance:By integrating capacitors directly onto the busbar with minimal interconnect distance, the entire power loop inductance (including capacitor ESL) is minimized. This is critical for reducing voltage overshoot, switching losses, and EMI in high-di/dt applications (e.g., SiC/GaN-based inverters).
- Superior Power Density & Space Savings:Eliminates separate capacitor mounting hardware and interconnecting cables/busbars, significantly reducing total assembly volume and weight for smaller, lighter end products.
- Enhanced Reliability & Simplified Assembly:Integrated single-unit design reduces mechanical connections by 50-70%, minimizing failure points and simplifying production with "plug-and-play" installation.
- Optimized Thermal & Electrical Performance:Strategic placement of capacitors and thermal vias optimizes current paths and heat dissipation, ensuring stable capacitor temperatures and extended lifespan.
- Total System Cost Reduction:Lowers overall costs through reduced assembly time, less hardware, simplified BOM management, and improved production yield.
Integrated Capacitor Busbar Design & Manufacturing Process
1. Custom Application-Specific Design:Every ICB is designed from the ground up for your specific IGBT/SiC module, capacitor requirements, and mechanical constraints
2. Complete Capacitor Sourcing & Integration:We manage full supply chain integration using proprietary connection technologies including ultrasonic welding and high-pressure diffusion bonding for superior electrical performance.
3. Advanced Multi-Physics Simulation:Comprehensive simulation validates parasitic inductance, thermal performance, and mechanical stress before prototyping.
4. Rigorous In-House Testing:Each assembly undergoes inductance measurement, Hi-Pot testing, insulation resistance verification, and environmental stress testing.
Integrated Capacitor Busbar Applications & Industry Uses
- Electric & Hybrid Vehicles (EV/HEV):Traction inverters, On-board Chargers (OBC), DC-DC converters
- Renewable Energy Systems:Solar inverters, Energy Storage Systems (ESS), Wind turbine converters
- Industrial Automation:High-performance motor drives, servo drives, UPS systems
- High-Power ICT & Telecom:Data center power supplies, telecom rectifiers
Why Choose A&J LINK for Your Integrated Capacitor Busbar?
- System-Level Engineering Expertise:We engineer complete power interconnect solutions considering electrical, thermal, and mechanical interactions holistically.
- Design for Manufacturing Excellence:Our designs are optimized for reliable, high-yield manufacturing from initial concept through production.
- End-to-End Project Ownership:We handle design, simulation, prototyping, testing, and volume production under one roof for seamless execution.
Get Your Custom Integrated Capacitor Busbar Solution
Contact our engineering team today to discuss how an A&J LINK Integrated Capacitor Busbar can optimize the heart of your power electronics system. Let us help you build a more compact, efficient, and reliable product.
FAQ
How is bus bar reliability ensured in high-vibration environments (e.g., electric vehicles)?
- We address this from three aspects: design, materials, and process:
- Design: Optimize structural rigidity to avoid resonant frequencies; design reliable mechanical locking and support structures.
- Materials: Use insulation films and adhesives with high bond strength; employ anti-vibration designs for terminals and connections.
- Process: Adopt permanent connections like welding or crimping instead of relying solely on bolts; use thread-locking adhesive on critical connection points.
- Validation: Perform standard vibration tests (e.g., GB/T 2423.10, IEC 60068-2-6) in-house or at third-party labs to simulate real-world operating conditions.
- Design: Optimize structural rigidity to avoid resonant frequencies; design reliable mechanical locking and support structures.
How is the current-carrying capacity of a bus bar determined, and what factors influence it?
- Current-carrying capacity is not a fixed value but is determined by a comprehensive electro-thermal balance. We determine the rated current through simulation and testing under the condition of meeting a specific temperature rise limit (e.g., ΔT ≤ 30°C).
- Main influencing factors include:
- Conductor Material & Cross-Sectional Area: Copper purity, busbar thickness and width.
- Insulation Material Thermal Conductivity: Thermal resistance of the insulation layer.
- Operating Environment & Cooling Conditions: Ambient temperature, cooling method (natural convection, forced air, attached heatsink).
- Installation Method & Adjacent Heat Sources: Busbar orientation, spacing, and heat generation from nearby components.
- Conductor Material & Cross-Sectional Area: Copper purity, busbar thickness and width.
What international certifications and standards do your products comply with?
- Our design, materials, and production processes adhere to several major international standards:
- Safety Standards: Compliant with UL94V0, ensuring products meet market access safety requirements.
- Industry Standards: Meet relevant specifications such as IEC and ISO. For the automotive industry, our processes comply with the IATF 16949 Quality Management System requirements.
- Material Certifications: The insulation materials used (e.g., PET, PI films) typically possess relevant UL recognition (e.g., UL 94 V-0 flame retardant rating).
- Safety Standards: Compliant with UL94V0, ensuring products meet market access safety requirements.
What are A&J LINK's production capabilities and quality control system like?
- Production Capabilities: We have full-process production lines, including precision stamping, laser cutting, CNC bending, hot pressing, ultrasonic welding, resistance/polymer diffusion welding, epoxy dip coating, and inline inspection equipment, capable of meeting needs from rapid prototyping to large-scale mass production.
- Quality Control: We implement a four-level control system: IQC (Incoming Quality Control), IPQC (In-Process Quality Control), FQC (Final Quality Control), and OQC (Outgoing Quality Control). Critical processes like insulation withstand voltage and loop resistance undergo 100% inspection. We implement automotive industry quality management methods like APQP and PPAP to ensure stable and reliable processes.
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