Laminated Busbar

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Laminated copper bars for low-inductance power distribution in renewable energy, electric vehicles, rail, and industrial electrical systems

Laminated busbars are compact, multi-layer conductive assemblies used for distributing power efficiently in high-current electrical systems. Instead of relying on traditional wiring, they integrate copper layers and insulation into a single solid structure, reducing wiring complexity and improving electrical performance.

Each busbar is made by stacking alternating layers of copper conductors and insulating materials such as epoxy resin or polyimide film, which are then bonded through heat and pressure. This layered structure minimizes inductance and electrical noise while improving reliability and consistency. It also saves space and simplifies installation in systems where clean layouts and stable power delivery are essential. Thanks to their low impedance, strong thermal stability, and ability to handle high current loads, laminated busbars are widely used in renewable energy systems, electric vehicles, rail transit, power inverters, and industrial automation.

Laminated busbars for inverters

Laminated busbars for renewable energy and traction equipment such as locomotives and mining vehicles

Laminated busbars used in rail transit systems for efficient power delivery

Laminated busbars suitable for wind and solar power systems to ensure steady energy flow

Features

Laminated busbars have a thin layered design with a broad heat dissipation surface and low impedance characteristics, which help reduce temperature rise and improve cooling efficiency. By sealing the edges through a hot-press process, laminated busbars gain higher strength and better heat resistance, allowing them to perform reliably over long periods.
Compared with cables of the same size, laminated busbars can carry more current and transmit power more efficiently. They handle up to 3300 V and 1200 A, making them suitable for high-power industrial systems.
Can be customized into various shapes, including L- and U-type bends, to simplify internal wiring and make better use of space inside electrical equipment.
The flat conductor arrangement minimizes electromagnetic interference and improves system stability, making these busbars ideal for applications with strict EMC requirements, including inverters and converters.
The flat, multi-layer structure of the laminated busbars, combined with low-dielectric insulation materials, keeps stray inductance and impedance low. This design minimizes transmission losses, reduces voltage spikes and electromagnetic interference during switching, and improves overall system stability.
The rigid multi-layer compact structure saves installation space and withstands harsh conditions such as high temperature and vibration, suitable for high-density applications in renewable energy systems, rail transit, and heavy-duty equipment.
Using standardized connection points and a hot-press forming process helps the laminated busbars fit neatly into the equipment layout. This makes installation faster and more accurate, reduces wiring work and overall costs, and leaves room for later adjustments or upgrades.

Specifications

Product type		Laminated Busbar
Conductor material		T2 copper/1060 aluminum/copper-clad aluminum Other materials are customizable upon request
Insulation voltage		300V–20kV
Max. withstand voltage		1000V–20kV
Rated current		0–4000A
Connection method		Copper plate press-fit Copper bar bolted Copper bar welded
Surface treatment		Tin plating, nickel plating, conductive oxidation, or anodizing Other surface treatments are customizable upon request
Interlayer adhesion strength		> 1300N (peel strength between laminated layers)
Insulation material		NOMEX, PVF, PET, PI, FR4, insulation powder, GPO3 Other materials are customizable upon request
Partial discharge		< 10PC
Parasitic inductance		15nH/m
Flame retardant rating		UL 94V-0
Insulation resistance		≥20MΩ, DC/1000V
Temperature rise		≤30K
Max. number of layer		6 layers
Max. dimensions		1000×1800mm (dimensions within this range customizable upon request)
Operating temperature		-40℃ to 105℃
Production capacity		20000 pcs/month
Delivery cycle		2–3 weeks (batch production: 3 weeks per 100 pcs, additional quantities as scheduled per contract)
Insulation material	Material properties	Density (g/cm³)	Thermal expansion coefficient	Thermal conductivity (W/kg.K)	Dielectric constant (f=60 Hz)	Dielectric strength (kV/mm)	Flame retardant rating	Heat resistance (°C)	Water absorption (%)/24h
	NOMEX	0.8–1.1	-	0.143	1.2	9	94, V-0	220	-
	PI	1.42	20	0.094	3.7	9	94, V-0	220	0.24
	PVF	1.38	53	0.126	10.4	19.7	94, V-0	105	0
	PET	1.38–1.41	60	0.128	3.3	25.6	94, V-0	120	0.1–0.2
	FR4	1.32	45–65	0.18	4.4	15.7	94, V-0	155	0.1–0.2

Injection-Molded Busbars

Injection-molded busbars are a newer type of busbar made to handle higher power levels without increasing the conductor size. They use advanced insulation and molding techniques that let them withstand higher temperatures, up to 125 °C, while keeping performance stable and reliable in demanding conditions.

Compared with other composite types, such as ROLINX Easy & Performance busbars, which typically operate at around 105 °C, this higher temperature rating gives them a clear advantage in high-power designs. Their enhanced insulation also enables long-term performance under extreme humidity conditions, such as 85 °C and 95% RH, far beyond the standard 55 °C and 95% RH operating limits. Injection-molded busbars are commonly used in equipment that runs on high power for long periods, such as industrial inverters, renewable energy converters, and heavy-duty traction systems found in trains, ships, and mining vehicles.

Specifications

Product type	Injection-Molded Busbar
Voltage	12kV, DC
Power rating	Kilowatt/Megawatt
Operating temperature	-50℃ to 125℃
Relative humidity	95%RH@55℃ (standard) 95%RH@85℃ (upgraded)
Conductor material	Copper/aluminum
Insulation material	Polyester dielectric film, rigid insulation board
Related tests	Partial discharge, high voltage and dimensional tests

Manufacturing Process

Technical meeting & project discussion

Engineering design and drawing/modeling

Workshop management office

Laser cutting area

Polishing & surface finishing area

Metal bending & forming area

Loading and transportation

Sheet metal bending

Epoxy insulation sheet cutting

Pressure riveting

Hot-pressing station 2

Hot-pressing station 3

Hot-pressing area

Trimming area

Trimming

Packaging area

Shipping & dispatch area

Applications

Frequency Converters
Wind and Photovoltaic Power Systems
Railway Transportation Systems
Automotive Industry

What type of power distribution component can replace traditional copper busbars in wind and solar power systems where large current transmission causes energy loss and space limitations?

In these cases, laminated busbars are a more efficient choice. Their layered copper and insulation structure makes the current flow path shorter, which helps reduce power loss by more than 30% compared with traditional copper bars. They also take up much less space, making them a good fit for compact installations like inverters and combiner boxes. The multi-layer design also minimizes electromagnetic interference, helping the system run smoothly even under high current conditions.

2.Why do laminated busbars have lower transmission losses compared with traditional copper bars, and what other benefits do they offer in high-power systems?

Laminated busbars are built with several layers of insulated copper foils arranged in parallel, which keeps the current path short and direct. This design lowers parasitic inductance and resistance by around 30–50%, helping reduce heat generation and energy loss. They’re also about half the size of traditional copper bars, making them ideal for compact equipment layouts. The layered structure improves heat dissipation and minimizes electromagnetic interference from high current, which helps protect nearby components and ensures stable operation in high-power systems such as wind inverters and energy storage PCS units.

Founded in 1995, Shanghai Wenlida develops and manufactures advanced voltage regulation and power quality equipment designed to maintain stable grid voltage levels, and ensure efficient and reliable operation of industrial and utility power systems.

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