Busbars

Busbars have been a key enabling technology in power applications for decades. They continue to play an important role across multiple industries — including automotive, industrial, green energy, public transportation, datacom & telecom and many others.

Being at the forefront of new innovations in busbar technology, Interplex’s busbar solutions provide for efficient and cost-effective integration within modern products and sub-systems that are smaller, faster and more complex.

By leveraging the expanded range and flexibility of these new busbar capabilities, engineers no long need to limit their designs to fit a few simplistic busbar approaches. Instead, they can choose from a widening range of busbar technologies and custom capabilities to fit their application-specific requirements.

Markets Served

Types of Applications

  • Molded Busbars for Automotive Power Steering integrate inductance units that receive and transmit signals to electric power steering ECU
  • Flexible Busbars in Electric and Hybrid Vehicles optimize ease-of-assembly and vibration resilience, while providing highly reliable connections to integrate large battery sub-systems and powertrains requiring high current-carrying capacity
  • Laminated Busbars in Power Circuits for Converters/Inverters integrate multi-layer connections within a single custom busbar, providing both simplification for assembly and enhanced reliability

Types of Busbars Available

Flexible Busbars

Flexible busbars consist of copper foils (“lamels”) made of high conductivity copper that are tightly bonded together at the mounting areas. Molecular diffusion welding bonds multiple sheets at the mounting area, while leaving the individual lamels separate along their length to provide flexibility throughout the rest of the busbar. As each lamel can slide against each other, our flexible busbars can be shaped, twisted and bent to adhere to the various space constraints of the particular system layout.

Interplex provides end-to-end design and manufacturing support for product engineers who need to incorporate flexible busbars into their systems. Prototypes can be created in as little as 7 days, followed by rapid ramp-up to volume production. As a vertically integrated global solutions provider, we can provide these solutions close to our valued customers.

Specifications:

  • Material: Copper foil
  • Lamel Thickness: 0.05 – 0.3mm, depending on specific application requirements
  • Structural Strength: 1.5 – 6mm thickness

Benefits of Interplex’s flexible busbars:

  • Excellent vibration and shock absorption
  • Improves electrical conductivity
  • Increases power efficiency
  • Maintains flexibility without compromising mounting strength or vibration absorption
  • High tolerance for assembly mismatch/offset
  • Easily customizable for compatibility with specific assembly environments

Our flexible busbars are used in the following industries and applications:

  • Automotive & Transportation – Electric, Hybrid and Fuel Cell vehicles
  • Industrial – Electrical connections in switch cabinets
  • Energy – Power links for generators, transformers, charging stations
Laminated Busbars

Laminated busbars consist of a multi-layer composite structure connected with a platoon; they can be regarded as a “multi-channel highway” for power distribution. In contrast to traditional, time-consuming and cumbersome wiring methods, the use of the laminated busbar approach provides modern, easy to design, quick to install, and well-structured distribution systems. Laminating multiple circuits within a single custom-designed busbar also provides simplification for assembly and enhanced reliability during operation. Our laminated busbars empower product designers with a space-efficient option for packaging, effectively delivering on overall electrical performance within the physical space constraints of a system.

Benefits of Interplex’s laminated busbars:

  • Repeatable and reliable electrical performance
  • Low impedance and low inductance (anti-interference)
  • Saves space
  • Simplified and quick assembly

Our laminated busbars are used in the following industries and applications:

  • Automotive & Transportation – Electric and Hybrid Vehicles, power and hybrid traction systems
  • Energy – Power generation systems, power conversion modules of electric equipment, power switch systems
  • Datacom & Telecom – Cellular communication, base stations, telephone exchange systems, large network servers, information storage systems, supercomputers
  • Industrial – Welding systems, motor drives
  • Aerospace – Aircraft, defense and military electronics
Overmolded Busbars

Overmolded busbars provide designers with a variety of options for vertical integration of packaging and insulation features to fit application-specific requirements.  Overmolding can help reduce flashovers and short circuits that can degrade performance and damage sensitive components.

Interplex offers a wide range of overmolding processes that can be combined with different underlying busbar technologies to customize the best-fit solution for specific design requirements.

Overmolding options include:

  • A wide range of molding materials
  • In-house compounding and mixing
  • Custom molding tool design
  • Automation-enabled high-throughput production capabilities
Customized Busbars

While busbars primarily perform electrical rather than structural functions, designers should consider how busbars mesh within the form factor constraints, provide structural integrity and optimize heat dissipation parameters.

Interplex offers an extensive range of capabilities for customizing our core busbar competencies to application requirements, as well as vertical integration options to take advantage of our broad spectrum of complementary technologies.

Customization options include creating unique busbar form factors, fulfilling various current-carrying capacities, designing multiple power lines, electronic packaging and sub-system integration.

Interplex in-house capabilities and expertise include:

  • Application expertise and design assistance
  • Production tooling design and build
  • Quick turn prototyping and design validation
  • Automation processes for high-volume production ramp-up
  • Global manufacturing options to accommodate logistics requirements

Our Portfolio