Laminated Busbar
Complete Guide & Overview

What is a Laminated Busbar?

A multi-layer power connection component with alternating conductive and dielectric layers, laminated under high pressure into a single unit. It replaces wire harnesses with a low-inductance, high-reliability power distribution backbone for IGBT, SiC, and GaN modules.

What insulation materials are commonly used for laminated bus bars, and how are they selected?

• Common Materials:​ Polyester (PET), Polyimide (PI/Kapton®), Polyvinyl Chloride (PVC) films, and epoxy resin coatings.

• Selection Criteria:​ Depends on application requirements:
  • PET:​ Cost-effective with good electrical and mechanical properties, suitable for most general applications.
  • PI:​ High-temperature rating (typically >200°C), chemical resistant, ideal for harsh environments.
  • PVC:​ Good flexibility, low cost, suitable for applications with lower temperature requirements.
  • Our engineers will recommend the optimal material based on your voltage rating, operating temperature, environmental regulations, and cost considerations.

What key parameters are needed to design a custom laminated bus bar?

• Electrical Parameters:​ Operating voltage, rated/peak current, frequency, target inductance/resistance values.
• Mechanical Parameters:​ Overall dimensions, mounting hole locations, position and type of connection terminals (screwed, welded, crimped, etc.).
• Thermal Parameters:​ Expected ambient operating temperature, cooling method (natural convection, forced air, attached heatsink).
• Application Information:​ Specific application scenario (e.g., PV inverter, EV motor controller) and layout of surrounding key components.

How does A&J LINK ensure the long-term reliability of laminated bus bars?

• Design Phase:​ Utilizes advanced multi-physics simulation (electrical, thermal, mechanical) for performance prediction and potential risk identification.
• Materials:​ Strictly certifies raw material suppliers to ensure copper purity and insulation film performance.
• Process:​ Employs precision stacking and hot-pressing processes to ensure bubble-free lamination and strong interlayer bonding.
• Testing:​ 100% electrical safety testing (e.g., Hi-Pot, insulation resistance) and sample-based reliability testing (e.g., thermal cycling, vibration testing).

What are the core advantages of laminated busbars compared to traditional copper busbars?

The core advantages focus on three aspects: electrical performance, space utilization, and reliability:
- In terms of electrical performance: The multi-layer structure shortens the loop distance, reduces parasitic inductance (usually down to below 10nH), minimizes switching losses, and is suitable for high-frequency power modules (such as SiC and GaN devices).
 In terms of space utilization: Through the alternating lamination of insulation layers and conductor layers, the installation volume is significantly reduced (under the same current-carrying capacity, the volume can be reduced by 30%-50%), making it suitable for compact scenarios such as new energy vehicle battery packs and energy storage inverters.
 In terms of reliability: The integrated structure reduces bolt connection points, lowering the risk of loosening under vibration. Additionally, the insulation layers (such as PP and PET) have a temperature resistance rating of over 120°C, adapting to harsh working conditions.

What is the lead time for your products?

• Lead times for standard products are typically shorter. For customized products, the timeline depends on design complexity and order quantity. Generally, prototype samples​ require 2-8 weeks, and mass production​ typically takes 3-6 weeks​ depending on scale. We are committed to providing the most competitive lead times while ensuring quality.