Busbars

 


Miltilayer Bus Bars (stacked conductive layers separated by dielectric and laminated into unified structure) help for lower inductance, improved reliability, increased capacitance and zero wiring errors, also offering unique features in mechanical design.

 

 

 

 

Advantages of using busbars

 

Busbar lowers the inductance
Using the overlapping parallel flat conductors with a thin dielectric laminated together and symmetrical reverse current paths provides the magnetic flux cancellation and much lower inductance. This leads to lower EMI, less commutation voltage spikes and higher possible operation frequency.

 

Busbar improves the reliability
Strict Electrical tests, thermal simulations and construction itself help to avoide unpleasant surprises in the field, also after years of operation.

 

Busbar increases capacitance
With a significant overlap area between layers and low distance between them provided by a thin dielectric with high K factor, the increased capacitance results in (1) additional drop of characteristic impedance, (2) greater effective signal suppression and (3) reduced noise. 

 

No more wiring errors
Replacing a set of cables with busbars eliminate the risk of wiring errors, simplify and speed-up the mounting process.

 

Busbar allows denser packaging
The use of wide and thin conductors laminated together decreases space requirements. Laminated busbars thus help decreasing the total system size and cost.

 

Busbar improves thermal characteristics
The controlled current distribution and use of  wide, thin conductors are favorable to allowing better airflow in systems. Thermal simulation and the even the possibility of making the liquid-cooled busbars keep the thermal parameters well under control. Thermal and electrical simulations can be done by Mersen engineers to evaluate the temperature rise and  current flow map (considering high frequency skin effect). This helps to identify the weak points prior to the production of the prototype. 

 

Busbars reduce system costs by decreasing assembly time and material handling costs having replaced numerous wires with one unit with no-guess connections.

 

 

 

Application examples

 

Photovoltaic
Multilayer laminated bus bar interconnects Diodes, IGBT modules and Capacitors within a  compact power inverter. Size: 16” x 28”  Voltage: 48V DC  Current: 240A

 

 

Hybrid Vehicles
Automotive grade reliability, two-layer busbar connects  parallel rows of batteries in a hybrid vehicle. Size: 3” x 4”   Voltage: 60V DC   Thickness: .093”   Current: 40A

 

 

City Transport
Robust two layer / four conductor laminated busbar for a Hybrid Transit Inverter. Laminated perimeter with sealed edge. Connects electrolytic capacitors, resistor networks and power modules.
Size: 10” x 11”,  1015V DC, 280A

 

 

Industrial Inverter
Uniting all electrical connections for IGBT modules, Capacitors, I/O and monitoring devices in one clean busbar improves overall system reliability and electrical performance.
Size: 16” x 28” 480V  240A