Laminated Busbar

What is a Laminated Busbar?

A laminated busbar is an advanced, multilayer power connection component. It consists of alternating layers of highly conductive copper or aluminum and thin, high-strength dielectric films (like PET or PI), laminated under high pressure into a single, compact unit. This integrated structure replaces messy wire harnesses, providing a clean, efficient, and reliable power distribution backbone for power modules (IGBT, SiC, GaN), capacitors, and other critical components.

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.