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Laminated Busbar Offers More Efficient Multiconductor Power Conversion

Storm Copper is Now STORM POWER COMPONENTS

Engineering design support, testing & time-critical delivery of high-end copper & aluminum electrical connectors.
 

 

Laminated bus grounding - a clean and efficient way to cut energy loss...

Copper bus bar laminations reduce inductance by alternating the positive and negative busbar layers between multiconducting layers of thin dielectric insulation. Multiconductor connectors of all makes and sizes, including IGBTs and capacitors, are connected to the structure. Inductance is reduced, electromagnetic interference is eliminated, and systems switch faster and cleaner, with less energy loss. The image to the right illustrates how Storm engineers transform a spaghetti harness into an integrated multi-layer bus system that you plug in and forget—along with complex wiring assembly, and costly installation errors.

Inductance, Capacitance, and Impedance in Laminated Bus Grounding Assemblies

Engineers are tasked to design a lamination that locates, shapes, and routes conducting points in ways to ensure that the multi-layered current can flow in opposite directions and in equal strength. The key aspect of this design is to generate opposing voltages proportional to the rate of current change in a circuit, which in turn enables the opposing magnetic fields to cancel each other's ticket. This eliminates a free ride for extra inductance.

Selecting the Best Geometries & Insulation Materials

With the guidance from our Insulation and Coating Center team, designers and engineers can be confident that they will make the right choice in insulating material and conductor (raw or plated copper) thickness. You’ll be able to explore design considerations from material to edge seals.

Edge Fills We Complete

  1. Open Edge
  2. Pinch Seal
  3. Epoxy Edge Fill

Samples of Edge Fills for Laminated Bus Bar

Whether the design calls for an open edge, pinch seal, epoxy edge fill, or a combination of laminated busbar edge geometries, we’ve got you covered. We’ll help you determine the component that is the best value, while balancing your product’s environmental and space demands. Although bus laminations have been around for almost two decades, newer, advanced insulating materials like Kapton and Teonex work in combination with improved design and fabrication techniques to utilize electric energy more efficiently, and save time and money. Selection of the proper internal dielectric insulations can depend on capacitance, inductance, voltage potentials, and operating environment. We have a variety of materials in-stock and ready for production. We also have UL-certified materials, and can also assist you in the creation of a custom product bulletin.

Insulation Materials Table Use Temp. Cº

 

Constant

Strength Rating
    ASTM D150 ASTM D149 (Volts per mil)  
Epoxy Glass (FR4)
Superior mechanical and dimensional stability
140 4.3 1250 UL 94 V-O
Mylar (PET)
Cost-effective, tear-, chemical-, and moisture-resistant
105 3.3 7500 UL 94 VTM-0
Tedlar (PVF)
Chemical/solvent resistant, good mechanical properties
105 11.0 3500 UL 94 HB
Teonex (PEN)
Higher deflective strength and continuous-use temperature
140 3.4 5000 UL 94 VTM-0
Nomex®
Flame-resistant, durable
220 1.6 430-845 UL 94 V-0
Kapton® (Polyimide)
High temperature rating and range stability
400 3.7 5000 UL 94 VTM-0
Epoxy Powder Coating
Flame- and moisture-resistant, ideal for multiple shapes
130 4.0 800 UL 94 V-0