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

  • Motor Stator Busbars enable designers of electric vehicle (EV) powertrains and other automotive functions to optimize motors for efficient current flow, custom form factors, thermal performance, faster assembly, volume production, and lower costs.
  • Overmolded and Complex Busbars provide fully customizable power interconnects combining application-specific 3D shapes with optimized electrical performance and integrated molding for complete solutions to streamline assembly and support high volume production.
  • Phase Busbars simplify the design and production of multi-phase interconnects between AC output of inverters and input to e-drive motors, featuring options such as laminated magnetic cores, integrated controls, gaskets, sealants, molding and flexible busbars.
  • Filter Modules & Assemblies provide customizable EMI noise solutions for EV power electronics to reduce noise emissions and/or protect against external noise sources.
  • BusMate® Power Busbar Connector Systems give designers robust small footprint pluggable solutions to minimize PCB real estate usage and maximize design flexibility.
  • 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
  • Molded Busbars for Automotive Power Steering integrate inductance units that receive and transmit signals to electric power steering ECU

Types of Busbars Available

Overmolded & Complex 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

Motor Stator Busbars

Interplex’s Motor Stator Busbar is a fully customizable electrical power interconnection solution connecting stator windings of an electric motor to a power source.

Flexibility and customization are key, and various design configurations can be explored. Our Motor Stator Busbar assemblies is typically a single part solution which provides a set of benefits to reduce the overall costs and improve the performance of connecting the electric motor to its power source.

Benefits of Motor Stator Busbars

  • Offers great flexibility for customized solutions
  • Improves electrical conductivity
  • Improves electrical performance with efficient designs
  • Reduces the size of a motor by eliminating complex cable connection
  • Reduces weight
  • Helps eliminate the wiring errors
  • Reduces assembly time
  • Simplifies the supply chain with a one-piece solution
  • Offers proven and reliable technology

Our Motor Stator Busbars Features

  • Low voltage, high voltage and high current applications
  • Compatible laser weld hairpin stator designs
  • Molded, overmolded and assembled construction
  • Materials and designs compatible with oil cooling requirements
  • Higher temperature materials
  • Typical size range: 30mm to 250mm diameter
  • Integrated phase connectors and interface options
  • Integrated high dielectric insulator options
  • Multi-layered busbar and coated wire construction options

Options for Motor Stator Busbars

  • Wire formed and stamped
  • Laser welded, brazing and pluggable
  • Integrated connector
  • Integrated sensing
  • Flexible phase connection

Our motor stator busbars are used in the following automotive applications:

  • Integrated drive modules
  • High voltage traction drive motors
  • 48V e-drive motors
  • Low voltage servo – steering and motion

Complex Busbars

Interplex’s Complex Molded Busbars provide an answer to the challenge faced by designers who need a fully customizable and flexible electrical power interconnect solution. In addition to safely conducting the electrical current between electrical components, our Complex Busbars improve the design flexibility with complex 3D shapes. This solution is ideal for high volume production and integrates connectors or structural functions, resulting in reduced weight and space savings.

Benefits of Complex Busbars

  • Offers great flexibility for customized solutions
  • Improves electrical conductivity
  • Compact design with controlled creepage & clearance distance
  • Reduces weight
  • Helps eliminate the wiring errors
  • Reduces assembly time
  • Simplifies the supply chain with a one-piece solution
  • Improves design flexibility with complex 3D shapes
  • Offers proven and reliable technology

Our Complex Busbars Features

  • High voltage and high current design options
  • Made of copper or aluminum – bare, tin or nickel plated
  • Multi-layer molded with high performance plastic and insulators
  • Inductance canceling design for WBG applications
  • Higher temperature materials

Options for Complex Busbars

  • High current, high voltage and high temperature
  • Dielectric insulator
  • Bolted and laser welded connection
  • Copper and/or aluminum
  • Integrated pluggable connector and Press-Fit
  • Integrated flexible busbar
  • Current sensing: Integrated laminate cores
  • Flame retardant UL94 V0, halogen free

Our complex busbars are used in the following automotive applications:

  • Integrated drive modules
  • Motor stators and phase connections
  • Inverter’s DC link bus & AC output side
  • By-pass filters
  • DC to DC converters
  • High voltage interface boxes

Phase Busbars Connectors

Interplex Phase Busbars Connector systems are typically used as a multi-phase interface between AC output of inverter and input of various types of e-drive motors.

These busbar connector systems can be fully customized and can feature various options like laminate magnetic cores for the current sensing, control connectors, gaskets & cured sealants, high performance plastics as well as flexible busbars connection options. Phase Busbars Connector products can be co-designed to be compatible with connections to Motor Stator Busbars and the inverter system, fully integrated drive modules and other e-motor drive applications.

Benefits of Phase Busbars

  • Offers great flexibility for customized solutions
  • Reduces weight
  • Helps eliminate the wiring errors
  • Reduces assembly time
  • Simplifies the supply chain with a one-piece solution
  • Offers proven and reliable technology

Our Phase Busbars Features

  • Multi-phase power interface
  • Low and high voltage application options
  • Integrated control circuit connectors
  • Current sensing: integrated laminate magnetic cores
  • Various sealing options: dispense and cure, gaskets and o-rings
  • Bolted, brazed & laser welded connection

Options for Phase Busbars

  • Sealed: Gasket and backfill design
  • Flexible power busbar
  • Stamped and machined contact designs
  • Copper and aluminum contact
  • Straight, 90 degree and custom angles
  • Screwed and bolt connection options

Our phase busbars are used in the following automotive applications:

  • Integrated drive modules
  • E-Motors systems
  • Inverter AC output
  • Low voltage servo – steering

Filter Modules & Assemblies

Power electronics conversion, high voltage batteries and drive motors are key components of Electric Vehicles (EV). Highly integrated power electronics inverters and converters generate EMI noise that can interfere with other power and electronics throughout the vehicle. In order to meet the challenges with Electromagnetic Compatibility (EMC), Interplex provides the complete low or high voltage Filter Module & Assemblies compatible with various EV power electronics systems. Interplex Filter Modules & Assemblies are designed to eliminate PCB with highly integrated components to provide to offer cost-effective solutions.

Benefits of Filter Modules & Assemblies

  • Designs to eliminate PCB boards
  • Helps eliminate the wiring errors
  • Reduces assembly time
  • Simplifies the supply chain with a one-piece solution
  • Offers proven and reliable technology

Our Filter Modules & Assemblies Features

  • Caps and wound chokes & ferrites​
  • Stamped & deep drawn metal ground covers
  • Direct laser welded connections​
  • Epoxy held components​
  • Designs accommodate stacked and multiple busbar construction​

Our Filter Modules are used in the following automotive applications:

  • High voltage inverters
  • 48V integrated inverter
  • EPS & Motion Control Servo Systems

BusMate® Power Busbar Connector System

Interplex’s BusMate® power busbar connector provides a small footprint to minimize PCB real estate usage and maximize design flexibility, while also delivering excellent electrical interface characteristics. By enabling a compact, solderless and economical interface for connecting busbars to a variety of small PCBs, BusMate® gives engineers a highly reliable and assembly-friendly solution for new power designs.

Benefits of Interplex’s BusMate®

  • Excellent ampacity-size ratio
  • Accommodates large mating tolerances: offset and angular

Our BusMate® Features

  • Low and high voltage applications
  • Compact size
  • Separable & pluggable
  • PCB Mount: Press-Fit and SMT
  • Customizable and scalable
  • High temperature construction: 125°C

Our BusMate® is used in the following automotive applications:

  • Hybrid Vehicle power systems
  • Low and high voltage power systems
  • DC to DC converters
  • On-board chargers
  • Charging systems

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
  • Product Thickness: 1.5 – 6mm

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

Our Portfolio