The Case for Longer Laminated Busbars and How to Manage Design Issues

Busbars have been evolving for over 100 years, with many waves of technology innovation continually expanding busbar capabilities to address new changing industry requirements. With the rise of new applications in the 2000s, extended-length busbars became necessary to distribute power efficiently across longer distances.

Some of the key drivers for long busbars include:

• Renewable Energy: Long busbars are essential for connecting solar farms and wind turbines spread over large areas.
• Data Centers: High-current busbars power server racks across expansive facilities.
• Transportation: Electric buses, rail systems, and ships need long, continuous power distribution systems.

Manufacturing improvements have also helped open the way for longer busbar designs, including:

• Advanced Lamination Techniques: High-precision lamination processes ensure consistent quality across long spans.
• Segmented Designs: Modular segments with interconnects to simplify transportation, installation, and maintenance.

As the industry leader in designing and manufacturing, Storm Power Components has perfected advanced processes for reliably creating custom designed laminated busbars with lengths of 20 feet or more. Key technologies include:

• Advanced Materials Technology: Development of high-conductivity copper alloys and lightweight aluminum composites has reduced resistive losses and overall weight.
• Lamination Improvements: Uniform adhesive distribution and precision pressing enable the production of consistent, reliable busbars up to 20 feet or more.
• Thermal and Electrical Modeling: Simulation tools allow Storm Power engineers to predict and mitigate heat buildup, voltage drops, and inductance over long spans.
• Precision CNC Machining: Turning and milling with multi-axis capabilities provides versatility for producing an endless array of copper or aluminum fabrications with tolerances as close as .001”.
• Press/Fused Welding: This manufacturing technique heats and squeezes individual copper laminates into a nearly solid copper bar state. Using copper sheets in varying sizes from 0.003” to 0.045” thickness positioned between heated graphite blocks, the process uses tonnage to press sheets together, creating a tight bond.

Read this new Storm Power Applications Note to learn more about Longer Laminated Busbars