Laminated Busbar For Large-Capacity Back-to-Back Converters
Products Description
Laminated Busbar for Large-Capacity Back-to-Back Converters are composite busbar assemblies made of alternating layers of copper conductors and thin insulating media. They are primarily used in high-capacity converters and UPS (Uninterruptible Power Supply) server systems to achieve low-inductance current transmission, voltage stabilization, and power distribution in high-voltage DC links.
They are suitable for scenarios requiring high power density, fast dynamic response, and reliable grid connection or energy storage conversion. They effectively reduce the stress impact of parasitic inductance on switching devices, improving the efficiency and stability of the entire system.
Product Nature and Characteristics
Product Definition: The DC-Link Capacitor Laminated Bus Bars is a composite laminated conductive connector. Its core feature is the alternating layering of conductive layers (copper or aluminum) and insulating dielectric layers (PET, FR-4, epoxy resin, etc.) through hot or cold pressing processes, forming a multi-layered structure with strict electrical clearances and creepage distances.
Key Feature Parameters for Laminated Busbars for DC Power Distribution Systems:
- Layer Count: Typically 2-10 layers, customizable according to current and voltage ratings
- Conductor Layer Thickness: 0.5mm-6mm, designed according to current density
- Insulation Layer Thickness: 0.1mm-1.5mm, withstand voltage rating 0.5kV-20kV
- Maximum Processing Size: 1000mm × 1800mm
- Flame Retardant Rating: UL94 V-0, Copper Laminated Bus Bars compliant with electrical safety standards
Manufacturing Advantages
| Material Cutting and Deburring | Precision cutting or CNC punching is used for Inverter Busbar for Rail Traffic to control the burr height to <0.05 mm, preventing tip discharge and insulation puncture. |
| Surface Treatment Uniformity | All parts are tin-plated (5–12 μm) or selectively silver/nickel-plated to ensure low contact resistance and long-term oxidation resistance with capacitor terminals and power module terminals. |
| Lamination and Curing Control | Precise closed-loop control of hot-pressing temperature, pressure, and time eliminates interlayer microbubbles (bubbles are the starting point of partial discharge), ensuring insulation withstand voltage reaches AC 3000V–5000V for 1 minute or higher for DC-Link Capacitor Laminated Bus Bars. |
| Three-Dimensional Precision Guarantee | CNC bending with dedicated anti-deformation fixtures controls springback, ensuring the coaxiality of mounting holes meets the requirements of M8/M10 bolts without forced alignment for Laminated Busbars for DC Power Distribution Systems. |
Product Advantages
Ultra-Low Stray Inductance Ensures Power Device Safety
The tightly laminated design reduces the stray inductance of the converter circuit to below 10nH, significantly suppressing voltage spikes caused by di/dt on the stray inductance during IGBT turn-off, thus reducing the risk of overvoltage breakdown in power devices. Actual test results show that the optimized Copper Laminated Bus Bars design can reduce the IGBT turn-off overvoltage of an 80kVA converter system by approximately 30%.
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Significantly Improved Space Utilization
The flat structure of the Inverter Busbar for Rail Traffic saves 30%–50% of installation space compared to traditional cable wiring, making the converter cabinet more compact and providing a hardware foundation for high power density designs.
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Significantly Improved Electromagnetic Compatibility
The multi-layered structure allows the electromagnetic fields generated by high-frequency switching currents to cancel each other outwards within the busbar, effectively reducing external radiation and minimizing electromagnetic interference to the control system and surrounding sensitive equipment.
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Excellent Heat Dissipation
The excellent thermal conductivity of the copper layer for DC-Link Capacitor Laminated Bus Bars, combined with the large-area flat structure, allows for rapid heat transfer from power devices to the cooling system, improving the system's thermal management efficiency and long-term reliability.
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contact us
For technical consultation or customization needs regarding Laminated Busbar for Large-Capacity Back-to-Back Converters, please contact us. We will provide you with detailed technical specifications, sample support, and engineering design services to help optimize your power system performance.
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