SOLUTIONS GUIDE

BUS BAR
SOLUTIONS
Electrical Power Distribution

Eldre | Ferraz Shawmut | R-Theta

ELDRE IS NOW MERSEN

ELDRE IS NOW MERSEN A REPUTATION FOR QUALITY

Eldre is now part of the Mersen family. Mersen is known Mersen’s reputation for outstanding technical expertise, product
worldwide for providing expertise to customers for safety and quality, and engineered safety is the result of over a century
reliability of electrical power. With the addition of Eldre to the of design and manufacturing knowledge, coupled with state-of-
Mersen family, Mersen adds laminated bus bar to its extensive WKHDUWHTXLSPHQWLQWKUHH,62UHJLVWHUHGIDFLOLWLHV(DFK
portfolio of products, creating a powerful bundled product facility manufactures single and multilayer bus bars, as well as
offering for the protection of power electronics. fully integrated solutions in which the laminated bus bar also
serves as a platform for a multitude of discreet components:
WHAT IS LAMINATED BUS BAR?
‡ In Europe, our 5,000 m2 plant in Angers is a center of
Laminated bus bar is an engineered component consisting of excellence for laminated bus bar solutions
layers of fabricated copper separated by thin dielectric materials,
‡ ,Q1RUWK$PHULFDRXUIW2 plant in Rochester, New
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York is a vertically integrated center of excellence for all
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multilayer bus bars that exceed 20 feet in length. Laminated bus
bar solutions are routinely used for low volumes up through tens ‡ In Asia, a brand-new 6,500 m2IDFLOLW\LQ6KDQJKDL&KLQD
of thousands per week. offers full manufacturing capability of all power and bus
bar solutions
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Bus bars reduce system costs, improve reliability, increase beginning of the design process, right through to the production
capacitance, and eliminate wiring errors. They also lower RI WKH ODVW SDUW 2XU 4XDOLW\ 6\VWHP LV GHVLJQHG ZLWK GHIHFW
inductance and lower impedance. Plus, the physical structure SUHYHQWLRQ LQ PLQG DQG LV FHUWL¿HG WR $6 2XU VWDII RI
of bus bars offers unique features in mechanical design. For professional engineers and experienced designers develops the
example, complete power distribution subsystems can also act tooling and manufacturing methods, procedures, and process
as structural members of a total system. Multilayer bus bars SDUDPHWHUVWRPHHWRXUFXVWRPHUV¶VSHFL¿FDWLRQV
offer a structural integrity that wiring methods just can’t match. With over sixty years of experience in designing laminated
bus bars and complete in-house manufacturing capability, we
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requirements through:
‡ quality control and quality assurance
‡ engineering and design
‡ chemical milling
‡ electroplating
‡ assembly
‡ epoxy encapsulation
‡ tool and die design and build
‡ metal fabrication
‡ metal joining
‡ die cutting
‡ laminating
‡ electrostatic powder coating

2 ep.mersen.com
POWER ELECTRONICS BUNDLING SOLUTIONS

TURN TO MERSEN FOR CUSTOMIZED ELECTRICAL PROTECTION SOLUTIONS

FOR POWER ELECTRONICS
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Mersen’s thermal protection and laminated bus bar offerings for
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designs. As a design partner with extensive application
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performance, lower total costs, and reduce time to market.
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a solution for you.

Laminated bus bar

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semiconductor fuses

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For Power Electronics solution inquiries,

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contact pesupport.nby@mersen.com
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Bus Bar 3
 PEACE OF MIND...
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SUPERIOR QUALITY FROM DESIGN

THROUGH MANUFACTURE
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shipments, Mersen provides customers with innovative power
distribution solutions. You’re always assured that we’ve omitted
nothing in our quest for customer satisfaction. Let us offer you
the same peace of mind that thousands of other companies have
enjoyed for more than 60 years. Here are just a few reasons:
‡ State-of-the-art metal fabrication is a key component
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fabricators, photo-chemical machining, production punch
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various edge conditioning processes. We offer a wide
range of metal joining processes including ultrasonic
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gold. Plating under tight, laboratory-controlled conditions,
we monitor and control plating thickness to required
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data monitoring, in-process controls, and x-ray testing
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‡ Precision manufacturing of dielectric components
is crucial in laminated bus bar production. To ensure
quality, we maintain calibrated humidity and temperature
controlled conditions to store our insulation. Precision
steel rule dies are used for cutting the insulation, ensuring
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‡ Properly selected insulation is the key factor to a
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of dielectric materials, including Nomex, Tedlar, Mylar,
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In addition to traditional sheet lamination systems, we
maintain our own electrostatic powder coating department
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protection for bus bars with geometric forms, or those
used in harsh environments.
‡ Assembly and Lamination is controlled using
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and manufactured for each bus bar. Hardware and
interconnection devices can be added before or after
the laminating and plating process.

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Bus Bar 5
POWER ELECTRONICS

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Thin copper conductors, separated by insulation material of only thousandths
of an inch, provides the ultimate in low inductance for IGBT-based motor
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packaging and reduces the effects of transient overshoots. Note the addition
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two-layer laminated bus bar providing a low inductance power path for
a low horsepower, variable speed motor drive. Note the use of a bonded
insulator strip along the length of the bus bar to provide additional
“creepage” protection between the plus and minus terminals.

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a new era of design sophistication began. The higher
switching speed of today’s IGBT demands a low
inductance power path which is uniquely delivered
by the Mersen laminated bus bar.

Mersen’s innovative Power Electronic designs provide

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“life blood,” securing the best suppression of parasitic
transients and safe operation for long life. The Mersen
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to provide perfect power and trouble-free service. A laminated bus bar assembly consisting of three power layers and one signal
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and complete gate drive circuitry all designed for a wave-solder assembly
Engage Mersen’s design team on your next project SURFHVV7KLVEXVEDULVXVHGLQDV\VWHPSRZHUHGE\026)(7V
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High-current circuit board design using laminated technology for IGBTs
and support components. Includes gold plating, quick connect mounting.
This laminated bus bar is an enhanced design of a typical IGBT bus
bar. Manufactured to be easily serviced, the design uses gold high
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mounting holes.

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Laminated bus bars provide a low inductance connection for capacitors.
The assembly was designed for an automated production process and the
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high-speed switching applications. Positive and negative layers are formed
and laminated without outside insulation. This design includes two rows of
capacitors soldered into position.

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and maintain tightly controlled coplanar mounting surfaces on both top and
bottom. Alternating the plus and minus layers throughout the assembly
counters the skin effect of high frequencies.

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High-frequency applications present a unique thermal challenge requiring the
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exceed conventional means of heat dissipation, one option is to add water-
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directly onto the epoxy powder coated conductors to maintain a constant
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a big role in the heat created from the bus and without this additional cooling,
the bus would surely overheat.

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Bus Bar 7
ALTERNATIVE ENERGY

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joins parallel rows of batteries together in a hybrid vehicle application.

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Multilayer, laminated bus bar used in a Photovoltaic Inverter application.
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compact power distribution structure.

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As the depletion of fossil fuels drives our attention

towards alternate energy sources to power our daily
lives, Mersen’s laminated bus bars can be found in
new, but familiar territory.

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low inductance laminated bus bars into an IGBT and
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our customers demand.

Mersen’s quality-engineered laminated bus bars use
state-of-the-art materials and manufacturing techniques
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This rugged two-layer, four-conductor bus bar is production built for a
Hybrid Transit Inverter application. The perimeter is a laminated sealed-edge
construction. It shows the system simplicity of combining capacitors and
IGBTs into a single bus bar system.

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and monitoring devices in one clean bus bar, overall system reliability is
improved and optimal electrical performance is assured.

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capacitors in a tight package in between two rows of IGBTs. This arrangement
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Bus Bar 9
TRANSPORTATION
Whether it’s carrying the high current necessary to
power heavy equipment, rail, and subway cars—or
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the latest aircraft and hybrid vehicles—Mersen laminated
bus bars bring unique advantages to the transportation
industry that are not available with traditional wiring or
single conductor bars. The electrical performance of
Mersen-engineered laminated bus bar is a key component
to success throughout the transportation industry.
A properly engineered laminated bus bar provides the
lowest overall system inductance and the most balanced
and distributed capacitance, making it the perfect match for
the high demands of the transportation equipment industry.
Mersen laminated bus bars help transportation equipment
manufacturers achieve their reliability goals, thus lowering
warranty costs and enhancing customer satisfaction.
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Fuel cells and hybrid electric vehicles require rugged, reliable power
distribution. Heavy duty construction with epoxy powder coating as a
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in harsh environments.
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Modern traction drives combine high current and high voltage in highly
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conductors, glass insulation spacers, and unique copper bushing “vias” to
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The laminated bus bar shown here represents a single-phase leg for a
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durability and continuous operation in hostile environments demand high
quality and consistency. The laminated bus bar has molded-sealed edges
and fully insulated mounting holes, built and tested to meet customer partial
discharge requirements.
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two-conductor laminated assembly includes bonded ceramic chokes, nylon
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board space while delivering low-impedance power to power-semiconductors
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for solderability and the entire assembly is formed at a right angle.

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Planar power technology is enhanced through laminating with thin dielectric
materials which yields a sealed, rugged structure. This design is formed into a
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Individually laminated, this two-conductor bus bar connects electrolytic
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made possible by Mersen laminated bus bars. Laminated bus bars are the
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the need for complex snubber circuitry. Laminated bus bar designs for motor
drives can contain a number of modular bus bars, linked together, to connect
all of the system components into one complete system.

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Bus Bar 11
DEFENSE & AEROSPACE

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temperatures from soldering. Made for a special defense application, the
design distributes power through wide tabs inserted and soldered into a
backplane. Power inputs are located at one end for easy connection with
a cable assembly.

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This complex, nine layer, low inductance laminated bus bar is engineered
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around each individual layer.

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defense and aerospace systems. That is why laminated
bus bars designed by Mersen are commonplace in a wide
range of defense applications, including missile guidance
equipment, phase-array radar systems, sonar and radar
tracking stations, airborne equipment, tanks, submarines,
and numerous space programs. Mersen’s laminated bus
bars offer other advantages for defense use, too. Their
superior electrical characteristics help defense systems
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Laminated bus bars are also known to provide the most
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compact means of packaging, achieving the highest overall
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And, because bus bars can be engineered to double as components and the other is densely populated with chip capacitors. The use
of Kapton insulation allows full solderability for surface mount components.
a structural support member, they contribute to system %RWKEXVEDUVDUHHSR[\HGJH¿OOHGDQGGHVLJQHGWRZLWKVWDQGH[WUHPHO\
strength and rigidity at the same time. If that’s not enough, demanding conditions of temperature and altitude.
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which makes it easier to keep mission critical equipment /HQJWKDSSUR[LPDWHO\HDFK_9ROWDJH9'&_&XUUHQW$_
up and running. &RQGXFWRUVDQG

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system delivers power and reliability over a long distance in a tight package.
Through the use of special “joiner bus bars,” the system is “daisy chained”
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High-current power distribution is easily handled with this six layer, twenty-
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backplane,” a bank of special connectors are soldered directly to the bus bar,
and used to distribute power within a turret control system.

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A complex and unique laminated bus bar design provides high-power
distribution over a backplane with solder tabs for output connectors and gold
plated input connections. This application for a laminated bus bar provides
power within a Missile Guidance system. The pluggable input connections
on this laminated bus bar are gold plated to provide low resistance and high
reliability between the bus bar and its subsystem. Forty pairs of outputs from
the bus bar to the backplane are made by solder connections. The bus bar is
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Bus Bar 13
INDUSTRIAL

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Mounted inside a circuit breaker power tray, individual bus bars are nested
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assures proper safety separation as well as single component installation.

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clinch hardware at each end. Its laminated, edge-sealed construction is
formed to stay out of the way within a tightly packaged medical testing device.

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The rough and rugged world of the industrial environment

demands a constant and consistent supply of quality
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Mersen’s industrial bus bar design solutions extend

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laminated bus bars to countless manufacturers of motor
drives, fork lift trucks, welding machines, power generators,
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characteristics, achieving a consistent level of performance
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that cannot be matched through wires, cables, or simple
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clean transition from power entry to motor windings. Glass mounting supports
are bonded to the structure creating a rigid installation.

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14 ep.mersen.com
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speed motor in a rugged industrial environment.

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input connections, including raised top contact surfaces to accommodate
snubber capacitors. High-temperature insulation material easily handles
the demanding thermal requirements.

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Bus Bar 15
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These assemblies use an edge sealed construction and employ a special
insulating washer that allows compression of the two conductors onto the
board while insulating the fastener from the live conductor.

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powder coating dielectric insulation for differing voltages. Power interconnects
directly from the power supply with included hardware so you get everything
in one rugged package.

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As data volume and broadband use continue to

expand, performance demands increase for high-speed
servers, blade servers, network backbone equipment,
engineering work stations, and such data storage
systems as disk arrays.

Mersen laminated bus bars help these computer equipment

designers meet that challenge, offering uncompromising
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computer equipment manufacturers with the ultimate
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necessary to satisfy the most demanding customers.

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laminated bus bars can also include thermal management,
with the bus bar acting as a heatsink. The bus bar’s
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a system where space is at a premium.

16 ep.mersen.com
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Modern supercomputer systems operate at extremely low voltages and
require a high concentration of current. This two-conductor bus bar assembly
is constructed from machined, stamped, and soldered components that are
insulated with a high-quality epoxy powder coating, then laminated together
to provide a low inductance power path distributed across a large circuit board
or backplane.

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Large parallel bars

carry a high degree
of current

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conductors is formed to
A pair of thinner, make connection points
laminated conductors
connect to the heavy-
duty bus bars to create
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bar structure

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with this two-conductor laminated bus bar complete with blind mate power
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monitoring. Formed tabs at bottom accommodate in-line fuse connections.

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Bus Bar 17
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integrated harness mates
power and signal together

High-current power connectors

are an integral part of the bus
bar system, enabling easy
installation of power supplies

Gold-plated, multilayer bus bars

mate with crown-edge type
connectors. This connector can
be production assembled to bus
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A second laminated bus bar plugs
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incorporates several different connectors for both power and signal, and
through careful engineering, a wire harness is used for signal distribution.
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Note three conductors tightly laminated through form

High-current connectors fastened to bus bar

18 ep.mersen.com
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Epoxy powder coating allows multiple conductors, formed to differing
geometries, to be assembled into a single unit. Insulated and bonded
together, this assembly carries power to the backplane without adding costly
and complex layers to the backplane.

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Redundant power supplies plug into this laminated bus bar design and
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ULJLGLQVXODWHGPRXQWLQJV\VWHP1LQH³&URZQ&OLS´KLJKFXUUHQWFRQQHFWRUV
distribute power from the power supply onto the backplane.

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from its power supply, through circuit protection, common and differential
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Power connector points

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Resistor and
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In the intensely competitive telecommunications market,
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Internet Routers must offer their customers exceptional
performance and dependability. With their consistent
quality, excellent electrical characteristics, minimal EMI,
RFI, and crosstalk, Mersen laminated bus bars provide
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Mersen laminated bus bars offer telecommunications
equipment manufacturers many other advantages too —
including ease of assembly, superior thermal management,
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effectiveness over alternative means of power distribution.
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An economical design that carries power from multiple power supplies
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and assembled together reducing a complex wiring scheme to a simple
component, saving both space and assembly time.
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dual power supplies across the backplane of an internet router. The insulation
system uses a molded-edge seal around the perimeter as a cost-effective
means of providing the proper creepage distance between the two conductors
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the low voltage of the system, Mersen engineers assure that the design has
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High-current pluggable connectors are mounted directly to the bus bar
for interchangeable power supplies.
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frame. The unit also has plated, soldered bushings for bullet-style
circuit breakers.

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When system requirements call for redundant power supplies, laminated bus
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input and mates downstream with a custom power distribution network.

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plane in a rack system for a network routing application. Heavy-gauge clinch
hardware and anti-rotation tabs accommodate cable connections. The entire
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When board space is at a premium, laminated bus bars provide the perfect
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includes an integrated connector, which allows for interchangeability of either
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routed through pluggable breakers and directed to output terminals within a
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LPSURYHGDLUÀRZ²ERWKNH\EHQH¿WVRIODPLQDWHGEXVEDUV

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Bus Bar 21
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Part of a rack-mounted circuit breaker network, this three-conductor,
single-layer laminated bus bar assembly is used to provide power
connections to a group of circuit breakers. Power connections are made
at each end and three banks of Faston tabs provide A, B, and Ground
connections for twenty circuit breakers.

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PEM hardware for

power input connection

Molded barriers for

connector isolation

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mount system

Faston tabs provide

quick-connect power
to circuit breakers

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clinch hardware, terminating in multiple power connectors mounted in a
8UDFNPRXQWHGSRZHUGUDZHU

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Three-phase shielded power is fed from a single power supply, extending
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to pass directly through the backplane, ensure high reliability and low contact
resistance connections to individual boards.

6L]H[_9ROWDJH9_&XUUHQW$_&RQGXFWRUV

22 ep.mersen.com
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series of blade-style pluggable output “tabs” along its length. The long,
narrow design makes short jump connections clean and easy for board
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ORZSUR¿OHGHVLJQDQGFOHDQGLVWULEXWHGFDSDFLWDQFHWKDWDUHWKHQDWXUDO
results of laminated bus bars.

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&XUUHQW$

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laminated bus bar through high-current power connectors and feed three
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through special silver-plated pins, installed as an integral part of the bus bar.

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Heavy-duty power
clips installed for mating
with power supplies

Power pins are

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Four-layer,
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bus bar

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Bus Bar 23
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Two large contactors

Two large capacitors

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Multilayer bus bars offer a structural integrity that wiring

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designs incorporate a variety of components built right in. 3'$81,7:,7+%86%$5
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help simplify your life at the system assembly level.

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Every day Mersen’s innovation delivers complete multi- design means 0XFKLPSURYHGDLUÀRZ
component bus bar and power distribution assemblies RQO\8KHLJKW
around the world to our dedicated family of customers. 6LJQL¿FDQWO\UHGXFHG
assembly time

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All wires replaced

by multilayer laminated
bus bar

“Plug-in” circuit breakers

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assembly weight

24 ep.mersen.com
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Multilayer bus bar

construction

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directly into bus bar

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due to capacitance in the
bus bar

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contactors

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bushings as “vias” to make
connections within the
laminated bus bar.

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Bus Bar 25
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makes easy connections to
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Easy connection
with contactors

Faston connections inside

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The design concept for this project was to create a rugged,

lightweight power distribution system for a production
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characteristics of the solid copper conductors used in
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success was achieved through compact packaging, light
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26 ep.mersen.com
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Main circuit breaker

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output bus bar

Plug-type output
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system installation
and eliminates
connection errors

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protection around high
current areas

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Electrolytic capcitors
enhance system
safety

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distribution. Along the top section, signal output reports system intelligence to
monitor each power supply’s performance.

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5$&.028173'$32:(5 6,*1$/

Plug-type circuit breakers

Integral wire feeds and connectors

help eliminate wiring errors

Elcon Rapid-Lock connectors

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high rack drawer

28 ep.mersen.com
 High-current power
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Electrolytic capacitors

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communication

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circuit breakers

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connections

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Mersen engineers work closely with customers to design complete rack
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LAMINATED BUS BAR DESIGN GUIDE

CONDUCTORS
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materials used are copper, aluminum, and a variety of copper
alloys. The material chosen, the mechanical constraints, and the
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Thermal considerations may require system ventilation to
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also serve to remove heat from components by performing as
a heat sink.
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thickness if there’s a need to accept studs, nuts, tabs or threaded
inserts. Minimum mechanical requirements for the connection
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effectiveness.

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circular mil area to its corresponding voltage conductor. A few
advantages of a separate ground return are:
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The physical structure of bus bars offers unique features in

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mechanical design. For example, complete power distribution  the opportunity for advantageous shielding between levels,
subsystems can also act as structural members of a total system. obtained by the use of interleaved grounds.
The proper design of bus bars depends on an application’s
mechanical and electrical requirements. This section includes
basic formulas and data to aid design engineers in specifying bus
EDUVIRUSRZHUGLVWULEXWLRQV\VWHPV2QFHDQRXWOLQHRIDEXVEDU
MOUNTING
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FRQVLGHUDWLRQVZLOODIIHFWWKHFRVW6HH&RVW&RQVLGHUDWLRQV KROHV HWF FDQ EH PDQXIDFWXUHG LQWR WKH FRQGXFWRUV $Q
alternative ground plane may be added as support for the bus
We’ve provided basic design criteria to help you specify bus bars
bar assembly and to provide a platform for mounting hardware.
for your application. The information required to specify a bus
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JURXQGGLPHQVLRQVOHQJWKZLGWKDQGWKLFNQHVVLQWHUFRQQHFWLRQ
VFKHPHVPRXQWLQJFRQ¿JXUDWLRQLIUHTXLUHGW\SHRI¿QLVKDQG
choice of insulation material.

30 ep.mersen.com
FINISH The equivalent circuit illustrates the associated inductance
/FDSDFLWDQFH&DQGUHVLVWDQFH5ZKLFKDUHPRVWRIWHQ
Mersen offers in-house conductor plating in tin, tin/lead, nickel,
uniformly distributed along the bus bar. We discuss the basic
silver, or gold. Plating is a major consideration in designing a
relationships between physical dimensions and electrical
bus bar because it is the point of contact for all bus bar electrical
parameters in the following analysis.
connections. The plating can provide advantageous electrical
properties, decreasing the voltage drop. When gold is used, it is
JHQHUDOO\RQO\SODWHGRQWHUPLQDWLRQVXUIDFHVWRPLQLPL]HFRVW

INSULATION
Bus bars use many different types of adhesive-coated insulation Figure 1. Figure 2.
materials to permit structure layers to be laminated together. 3K\VLFDO5HSUHVHQWDWLRQ (OHFWULFDO(TXLYDOHQW
7KHUH DUH DGGHG EHQH¿WV IURP DQ HOHFWULFDO SHUVSHFWLYH
Insulation provides an inside and outside barrier to its installed CONDUCTOR SIZE
environment. Insulations can increase the capacitance and
&DOFXODWLQJFRQGXFWRUVL]HLVYHU\LPSRUWDQWWRWKHHOHFWULFDODQG
ORZHUWKHLQGXFWDQFHDQGLPSHGDQFH&RPPRQO\XVHGLQVXODWLRQ
mechanical properties of a bus bar. Electrical current-carrying
materials are Nomex®, Tedlar®, Mylar®, Kapton®8OWHP®, Mylar/
requirements determine the minimum width and thickness of
7HGODU 7HGODU0\ODU7HGODU 9DOR[®, epoxy-glass, heat shrink
the conductors. Mechanical considerations include rigidity,
tubing, and epoxy powder coating. There are many different
mounting holes, connections, and other subsystem elements.
WKLFNQHVVHV RI WKHVH LQVXODWLRQ PDWHULDOV DYDLODEOH &RQWDFW D
The width of the conductor should be at least three times the
0HUVHQ HQJLQHHU IRU PRUH LQIRUPDWLRQ 6SHFLDO LQVXODWLRQV DUH
thickness of the conductor.
available upon request.
Additions of tabs and mounting holes change the cross-sectional
area of the conductor, creating potential hot spots on the bus
COST CONSIDERATIONS bar. The maximum current for each tab or termination must be
considered to avoid hot spots.
Prices of bus bar assemblies vary depending upon quantity
&URVVVHFWLRQDO DUHD DQG WKH OHQJWK GHWHUPLQH EXV EDU
ordered. In addition, individual dimensional characteristics,
FRQGXFWRUVL]H&URVVVHFWLRQDODUHD$LVHTXDOWRFRQGXFWRU
materials, manufacturing techniques, the interconnection
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VFKHPH SODWLQJ ¿QLVK LQVXODWLRQ DQG KDUGZDUH UHTXLUHPHQWV
affect overall cost.
Mersen engineers are available to assist in developing the most
HI¿FLHQW DQG FRVWHIIHFWLYH GHVLJQ WR SURYLGH VROXWLRQV WR DQ\
power distribution problem. The earlier we are involved in your
design process, the more cost effective your solution is likely
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$ YDOXH RI DSSUR[LPDWHO\  FLUFXODU PLOV SHU DPSHUH LV D
WUDGLWLRQDOEDVLVIRUGHVLJQRIVLQJOHFRQGXFWRUV6LQFHEXVEDUV
are not round, circular mils must be converted to mils squared
WR EH (DUO\ LQYROYHPHQW HQDEOHV XV WR RSWLPL]H ERWK HDVH RI
manufacturing and turnaround time. We recommend that you
contact a new-product development engineer before you start
designing your laminated bus bar power distribution system.
ELECTRICAL DESIGN
Important characteristics of laminated bus bars are resistance,
series inductance, and capacitance. As performance parameters
VLPSO\PXOWLSO\WKHFLUFXODUPLOVYDOXHE\
The following formula determines the minimum cross-sectional
DUHD RI D FRQGXFWRU 7KLV DUHD VKRXOG EH LQFUHDVHG E\ ¿YH
percent for each additional conductor laminated into the bus
VWUXFWXUH7KLVH[WUD¿YHSHUFHQWLVDVDIHW\IDFWRUFRPSHQVDWLQJ
for the compounding heat gain within the conductors.
This equation calculates the minimum cross-sectional area
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of electronic equipment and components become more
stringent, these characteristics take on even more importance.
In determining the impedance of a power distribution system,
WKHVH FKDUDFWHULVWLFV DUH VLJQL¿FDQW LQ VROYLQJ WZR RI WKH PRVW
important problems for designers—resistance and noise. It is
important, therefore, to understand the electrical characteristics
of the laminated bus bar.
)LJXUH  VKRZV D EDVLF WZRFRQGXFWRU ODPLQDWHG EXV EDU DQG
A I>N@*-6LQFKHV2
A = cross-sectional area of the conductor in inches2
, 0D['&FXUUHQWLQDPSHUHV
N = Number of conductors in the bus assembly
7RFDOFXODWHWKHFURVVVHFWLRQDODUHDRIDQ$&FXUUHQWVRXUFH
\RXPXVWWDNHIUHTXHQF\LQWRFRQVLGHUDWLRQVHHWKHVHFWLRQRQ
Figure 2 shows its equivalent circuit. The bus bar is composed 6NLQ(IIHFW
of two parallel conducting plates separated by a dielectric.

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Bus Bar 31
1RWH7KLVIRUPXODKDVDEUHDNGRZQSRLQWDWDSSUR[LPDWHO\
amps of current. For calculations involving larger currents, we
suggest you contact a Mersen engineer. In addition, you can
¿QG DPSDFLW\ FKDUWV DQG FRPSDUDWLYH JUDSKV DW WKH &RSSHU
'HYHORSPHQW$VVRFLDWLRQ¶VZHEVLWHZZZFRSSHURUJ
CAPACITANCE
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PDWHULDO DQG SK\VLFDO GLPHQVLRQV RI WKH V\VWHP &DSDFLWDQFH
varies only slightly with frequency change, depending on the
stability of the dielectric constant. This variation is negligible and
therefore is omitted in this analysis:
INDUCTANCE
Maintaining a low inductance results in a low characteristic
impedance and greater noise attenuation. When minimum
inductance is a design objective, consider these tips:
 0LQLPL]HWKHGLHOHFWULFWKLFNQHVV
2. 0D[LPL]HWKHFRQGXFWRUZLGWK
 Increase the frequency.
There are two types of inductance to be determined: internal
LQGXFWDQFHZKLFKLVDUHVXOWRIÀX[OLQNDJHVZLWKLQDFRQGXFWRU
and external inductance, which is determined by the orientation
of the two current-carrying conductors.
C = KZl picofarads 'LVWULEXWLRQRIFXUUHQWWKURXJKRXWDFRQGXFWRUDWKLJKIUHTXHQFLHV
G
Increased capacitance results in a decreasing characteristic
impedance. Low impedance means greater effective signal
suppression and noise elimination. It is therefore desirable to
develop maximum capacitance between conductor levels. This
may be achieved by:
 keeping the dielectric as thin as possible, consistent
with good manufacturing and design practices
2. using dielectrics having a high relative permittivity
LV FRQFHQWUDWHG QHDU WKH VXUIDFHV FDOOHG WKH ³VNLQ HIIHFW´
7KHLQWHUQDOÀX[LVUHGXFHGDQGLWLVXVXDOO\VXI¿FLHQWWRFRQVLGHU
only the external inductance. At low frequencies, however, the
internal inductance may become an appreciable part of the total
inductance. The formula for calculating the internal inductance
at a low frequency is extremely lengthy and thus omitted in
this analysis.
The formula for external inductance is:
NIDFWRU
L = Glnanohenrys
Z

SKIN EFFECT +LJK)UHTXHQF\,QGXFWDQFHW!SD

Because of skin effect phenomena, inductance and resistance

Lt = GSDlnanohenrys
are dependent on frequency. At high frequency, currents tend to Z
ÀRZRQO\RQWKHVXUIDFHRIWKHFRQGXFWRU7KHUHIRUHWKHGHSWK
of penetration of the electromagnetic energy determines the
effective conducting volume. RESISTANCE
7RFDOFXODWHWKH'&FRQGXFWRUUHVLVWDQFHWKHIROORZLQJIRUPXOD
DSSOLHV5HVLVWDQFHDWƒ&
The skin depth is given by:

5DC = ȡlohms

SD =  inches Zt
¥›IMȡ
5DC = * lohms
-6

)RU&RSSHU Zt

SD = 2.6 inches 7R GHWHUPLQH '& FRQGXFWRU UHVLVWDQFH DW WHPSHUDWXUHV DERYH
¥I
ƒ&XVHWKLVIRUPXOD

As frequency increases, inductance decreases to a limiting Į 7HPSFRHI¿FLHQWRIUHVLVWLYLW\RIFRSSHUDWƒ&LV

YDOXH ZKHUHDV WKH UHVLVWDQFH LQFUHDVHV LQGH¿QLWHO\ DV WKH
IUHTXHQF\DSSURDFKHVLQ¿QLW\ 52 = 5T2-TRKPV
52 = Resistance at elevated temp

R2 5HVLVWDQFHDWHOHYDWHGWHPSHUDWXUH72
5 5HVLVWDQFHDWƒ&7

32 ep.mersen.com
For high frequencies the skin depth is taken into consideration.
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7KHIRUPXODIRU$&UHVLVWDQFHLV
)RUW!6' A &URVVVHFWLRQDODUHDRIDFRQGXFWRULQLQFKHV2

5AC = 2lȡ ohms C &DSDFLWDQFHLQSLFRIDUDGV

SDZ
˜ Thickness of dielectric in inches
$&UHVLVWDQFHDWƒ&
ȡ Resistivity of the conductor in ohms/inch
5AC = 2l* ohms
-6

SDZ I )UHTXHQF\LQKHUW]

I &XUUHQWLQDPSV

VOLTAGE DROP K 'LHOHFWULFFRQVWDQW

As current travels across a conductor, it loses voltage. This
is caused by the resistivity of the conductor. The losses are
l Length of conductor in inches

UHIHUUHG WR DV YROWDJH GURS 8VH WKLV IRUPXOD WR FDOFXODWH WKH L Inductance in nano henrys
voltage drop across the conductors:
Lt Total inductance at high frequency
VD 5I
Permeability of nonmagnetic
M
5 = ȡlohms PDWHULDOV *KHQU\VLQFK
Zt
R Resistance in ohms

VD = ȡIl9ROWV 6' 6NLQGHSWKLQLQFKHV

Zt
t Thickness of the conductor in inches

IMPEDANCE T 7HPSHUDWXUHDWSRLQWLQ&o

In the design of laminated bus bars, you should consider T2 7HPSHUDWXUHDWSRLQWLQ&o

maintaining the impedance at the lowest possible level. This
ZLOOUHGXFHWKHWUDQVPLVVLRQRIDOOIRUPVRI(0,HOHFWURPDJQHWLF w Width of conductor in inches
LQWHUIHUHQFHWRWKHORDG
9d 9ROWDJHGURSLQYROWV
Increasing capacitance and reducing inductance are the
determining factors in eliminating noise. › 3L 
The formula for calculating characteristic impedance is:
Į Temperature coeffecient of resistivity
Z = ¥L/C ohms
] Impedence

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Bus Bar 33
RESISTANCE, INDUCTANCE, AND CAPACITANCE COMPARISONS

TWISTED PAIR MERSEN BUS BARS

$:*ZLUHVROLG²ORQJ 0HUVHQEXVEDU²ORQJ[ZLGH[WKLFN
,QVXODWLRQWKLFNQHVVDSSUR[  ,QVXODWLRQWKLFNQHVV $0521Œ²
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Freq (Hz) RAC (ohms) /ȝKHQU\V C (pfds) Freq (Hz) RAC (ohms) /ȝKHQU\V C (pfds)

 0.006  50.0   0.0200 

6    6  0.0060 

       

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Freq (Hz) RAC (ohms) /ȝKHQU\V C (pfds) Freq (Hz) RAC (ohms) /ȝKHQU\V C (pfds)

   52.5    

6    6   

   52.0    

34 ep.mersen.com
TYPICAL CONVERSION CHARACTERISTICS
Current
DC Resistance
Wire Size Carrying
RAC (ohms) Cir Mils Sq Inches Thick (in.) Width (in.) of a 2-Conductor
Gauge Capacity
Bus (milliohm/ft)
(amps)

22   .0005 .005   

   .0020 .005   

    .005   5.05

       2.00

       

       .500

0      252.00 .200

00       

INSULATION AMRON 5:6HULHVLVDOVRDFRPSRVLWH¿OPPDGHXSRI$PURQ

 DQG$PURQ  7KHVH ¿OPV DUH XVHG DV LQWHUQDO LQVXODWLRQ
0HUVHQ XWLOL]HV PDQ\ LQVXODWLRQ V\VWHPV WR PHHW GLIIHUHQW
and are recommended for high dielectric strength applications
applications. These systems combine the dielectric materials
7HGODU0\ODU7HGODU
detailed in the table on the next page. By combining different
materials with selective edge-conditioning techniques, our AMRON 6: 6HULHV  DUH SRO\HWK\OHQH WHUHSKWKDODWH 3(7
insulating systems are designed to exceed any and all of your ¿OPV3(7DUHSRO\HVWHU¿OPVZKLFKRIIHUDQH[FHOOHQWEDODQFH
electrical, mechanical, and environmental requirements. RIHOHFWULFDOFKHPLFDOWKHUPDODQGSK\VLFDOSURSHUWLHV7UDGH
$PURQŒGLHOHFWULFSURGXFWVZHUHVSHFL¿FDOO\GHYHORSHGIRU
use in the manufacture of bus bars. Many of the products
are coated with a B-stage resin that is reactivated during the
DVVHPEO\ SURFHVV 0RVW RI RXU LQVXODWLQJ V\VWHPV DUH 8/
name: Mylar®
AMRON 7:6HULHVLVDFRPSRVLWHLQVXODWRUPDGHXSRI$PURQ
2 and Amron 6. This composite combines the mechanical
toughness of Nomex with the electrical properties of Mylar
5HFRJQL]HG 5HIHUHQFH ZZZXOFRP IRU D PDWHULDO OLVWLQJ 1RPH[0\ODU1RPH[
)LOH1R( AMRON 8: 6HULHV  DUH ODPLQDWHG VKHHWV FRQVWUXFWHG IURP
AMRON 1:6HULHVDUHSRO\YLQ\OÀXRULGH39)¿OPV39) FRQWLQXRXV¿ODPHQW W\SH JODVV IDEULF ZLWK D ÀDPHUHWDUGDQW
¿OPV DUH FKHPLFDO DQG VROYHQWUHVLVWDQW GHPRQVWUDWH epoxy resin binder. Good fabrication, high dielectric, and
excellent molding characteristics, and have both a high physical strengths make this material suitable for many
GLHOHFWULF FRQVWDQW .IDFWRU DV ZHOO DV D KLJK GLHOHFWULF HOHFWULFDODSSOLFDWLRQV1(0$*UDGH)5
VWUHQJWK7UDGHQDPH7HGODU® AMRON 9: 6HULHV  DUH HSR[\ SRZGHU FRDWLQJV 7KHVH
AMRON 2: 6HULHV  DUH DURPDWLF SRO\DPLGH SRO\PHU FRDWLQJV H[KLELW H[FHSWLRQDO GXUDELOLW\ $PURQ  VKRXOG EH
papers. Mechanical toughness, thermal stability, and used where conventional insulation, due to part geometry, is
VROYHQW UHVLVWDQFH DUH VRPH RI LWV FKDUDFWHULVWLFV 7UDGH not practical.
name: Nomex®
AMRON 3: 6HULHV  DUH SRO\LPLGH ¿OPV 7KHVH ¿OPV DUH Note: The insulations listed above are standard materials
UHFRPPHQGHG IRU KLJK WHPSHUDWXUH DSSOLFDWLRQV 7UDGH used in the manufacture of our bus bars. Many other dielectric
name: Kapton® PDWHULDOV DPRQJ WKHP 9DOR[® 8OWHP®, and PEN, can be
AMRON 4:6HULHVLVDFRPSRVLWH¿OPPDGHXSRI$PURQ LQFRUSRUDWHGLQWR\RXUGHVLJQWRPHHWVSHFL¿FUHTXLUHPHQWV
 DQG $PURQ  8VHG H[FOXVLYHO\ DV RXWVLGH LQVXODWLRQ Be sure to consult with a Mersen application engineer in
WKHVH ¿OPV SURYLGH DQ H[FHOOHQW VFXIIUHVLVWDQW FRDWLQJ VHOHFWLQJ LQVXODWLRQ DV YDOXHV PD\ ÀXFWXDWH DIWHU LQVXODWLRQ
0\ODU7HGODU has been applied.

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Bus Bar 35
BUS BAR INSULATION TECHNIQUES

*/$66('*(),//(' (32;<('*(),//('
&216758&7,21 &216758&7,21

Edge insulation: Epoxy

Epoxy Glass Typical HGJH¿OO

Internal Insulation
&RQGXFWRU/D\HU
&RQGXFWRU/D\HUV
&RSSHURU$OXPLQXP Insulator Layers
External Insulation

6LPSOHFRQVWUXFWLRQ
/DPLQDWHG36$WDSH
or Ty-Wrap assembly
Radiused edges
of copper Multiple colors available

(32;<32:'(5&2$7,1*

23(1/$0,1$7('&216758&7,21 02/'('6($/('&216758&7,21

36 ep.mersen.com
STANDARDS
7KHVHOLVWVGHWDLOWKHVSHFL¿FDWLRQVWKDWRXUVWDQGDUGFRQGXFWRUPDWHULDOLQVXODWLRQDQGSODWLQJSURFHVVHVPHHW,QFRUSRUDWLQJWKHVH
VWDQGDUGVLQWR\RXURZQVSHFL¿FDWLRQVQRWHVZLOOKHOSUHGXFHPDQXIDFWXULQJFRVWVDQGUHGXFHF\FOHWLPHV

Conductor Material Plating

&'$ &RSSHU $670%% Tin $670%

&'$ Brass $670% Nickel 441$06

Phosphate Electroless
&'$ $670% 0,/&
%URQ]H Nickel
Beryllium 6XOIDPDWH
&'$ $670%% 0,/3
&X Nickel

&'$ &RSSHU$OOR\ $670% Gold $670%

$OOR\ Nickel/Iron $670) 6LOYHU 446

Alloy &RSSHU $06

+ $670%
Aluminum
Tin-Lead
$063$670%


Insulation Tin-Lead
0,6

$PURQ Tedlar®39) /3
$QRGL]H 0,/$
Amron 2 Nomex® 0,/,
&KURPDWH 0,/&
$PURQ Kapton® 0,/3
Passivate 443
Amron 6 ®
Mylar /PET 0,/,

$PURQ )5 0,/,

Epoxy
$PURQ Powder $670'
&RDWLQJ

$PURQ 8OWHP®

$PURQ 9DOR[®

Epoxy Edge Black or

0,/,
Fill White

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Bus Bar 37
GLOSSARY OF TERMS

Capacitance Impedance
Measured in farads, it is the opposition to voltage changes in an alternating
FXUUHQWFLUFXLWFDXVLQJYROWDJHWRODJEHKLQGFXUUHQWH[KLELWHGE\WZR
conductors separated by an insulator.
Capacitor
A passive electronic component that stores energy in the form of
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conducting plates separated by an insulating material called the dielectric.
The capacitance is directly proportional to the surface areas of the plates,
and is inversely proportional to the separation between the plates.
&DSDFLWDQFHDOVRGHSHQGVRQWKHGLHOHFWULFFRQVWDQWRIWKHPDWHULDO
separating the plates.
Choke
An inductor designed to present a high impedance to alternating current.
Clearance
7KHFOHDUDQFHLVGH¿QHGDVVKRUWHVWGLVWDQFHWKURXJKWKHDLUEHWZHHQWZR
conductive elements.
Common Collector Connection
6DPHDVJURXQGHGFROOHFWRUFRQQHFWLRQ$OVRFDOOHGWKHHPLWWHUIROORZHU
A mode of operation for a transistor in which the collector is common to
both the input and the output circuits and is usually connected to one of
the power rails.
Common Emitter Connection
6DPHDVJURXQGHGHPLWWHUFRQQHFWLRQ$PRGHRIRSHUDWLRQIRUDWUDQVLVWRULQ
which the emitter is common to the input and output circuits. The base is the
input terminal and the collector is the output terminal.
Conductivity
How easily something allows electric current to pass through it. If a substance
=0HDVXUHGLQRKPVLWLVWKHWRWDORSSRVLWLRQWRWKHÀRZRIFXUUHQW
offered by a circuit. Impedance consists of the vector sum of resistance
and reactance.
Insulation Resistance
The resistance offered, usually measured in megaohms, by an insulating
PDWHULDOWRWKHÀRZRIFXUUHQWUHVXOWLQJIURPDQLPSUHVVHG'&YROWDJH
Insulators
0DWHULDOVZKLFKSUHYHQWWKHÀRZRIHOHFWULFLW\1RQFRQGXFWLYHPDWHULDOVXVHG
to separate electric circuits.
Inverter
An electric or electronic device for producing alternating current from
direct current.
Partial Discharge
$W\SHRIORFDOL]HGGLVFKDUJHUHVXOWLQJIURPWUDQVLHQWJDVHRXVLRQL]DWLRQLQDQ
insulation system when the voltage stress exceeds a critical value.
Resistance
RDQGPHDVXUHGLQRKPV2SSRVLWLRQWRFXUUHQWÀRZDQGGLVVLSDWLRQRIHQHUJ\
in the form of heat.
Self-inductance
The property of a conductor that produces an induced voltage in itself
with changing current. The term inductance alone means self-inductance.
When a varying current in one conductor induces a voltage in a neighboring
conductor, the effect is called mutual inductance.
Shield
3DUWLWLRQRUHQFORVXUHDURXQGFRPSRQHQWVLQDFLUFXLWWRPLQLPL]HWKHHIIHFWV
RIVWUD\PDJQHWLFDQGUDGLRIUHTXHQF\¿HOGV
LVDJRRGFRQGXFWRURUKLJKO\FRQGXFWLYHIRUH[DPSOHFRSSHURUEUDVVLWZLOO
allow electrons to pass freely through it, offering only minor resistance. Shunt
A low-value precision resistor used to monitor current.
Corona
$OXPLQRXVGLVFKDUJHGXHWRLRQL]DWLRQRIWKHDLUVXUURXQGLQJDFRQGXFWRU Snubber
caused by a voltage gradient exceeding a certain critical value.
Corona Extinction Voltage (CEV)
7KHKLJKHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVH
amplitude no longer occurs, as the applied voltage is gradually decreased
from above the corona inception value.
Corona Inception Voltage (CIV)
7KHORZHVWYROWDJHDWZKLFKDFRQWLQXRXVFRURQDRIVSHFL¿HGSXOVHDPSOLWXGH
occurs as the applied voltage is gradually increased.
$UHVLVWRUFDSDFLWRU5&QHWZRUNXVHGWRUHGXFHWKHUDWHRIULVHRIYROWDJHLQ
switching applications.
Voltage Drop
&RQGXFWRUVFDUU\LQJFXUUHQWDOZD\VKDYHLQKHUHQWUHVLVWDQFHRULPSHGDQFH
WRWKHFXUUHQWÀRZ9ROWDJHGURSLVWKHDPRXQWRIYROWDJHORVVWKDWRFFXUV
through all or part of the circuit due to impedance.
THREE-LAYER BUS BAR

Creepage Distance
WITH INDEPENDENT
The shortest distance separating two conductors as measured along a FASTON TABS AT
surface touching both conductors.
LONG END
Dielectric
1RQFRQGXFWLQJPDWHULDOXVHGWRLVRODWHDQGRULQVXODWHHQHUJL]HG
electrical components.
PRESS-FIT BUSHINGS
Dielectric Constant (K)
The property of the dielectric material that determines how much electric WITH CROWN BAND
HQHUJ\FDQEHVWRUHGLQDFDSDFLWRURIDSDUWLFXODUVL]HE\DYDOXHRI
INSERTS
applied voltage.

Dielectric Strength
The maximum voltage an insulating material can withstand without
breaking down.

EMI, RFI
FLEXIBLE TABS FOR LOW
Acronyms for various types of electrical interference: electromagnetic PROFILE AREAS
interference and radio-frequency interference.

Hi-Pot Test (High Potential Test)

$WHVWSHUIRUPHGE\DSSO\LQJDKLJKYROWDJHIRUDVSHFL¿HGWLPHWRWZR
isolated points in a device to determine the adequacy of insulating material.

38 ep.mersen.com
FASTON TABS FROM BOLT ON TABS
INSIDE THE BUS BAR, CONFINED WITHIN THE
SAVES SPACE BUS BAR, SAVES SPACE
AND MATERIAL

PANEL HARDWARE CLINCH HARDWARE

FOR RING LUGS

SQUARE PINS FOR FASTON TABS EXTENDING

SOLDER CONNECTIONS BEYOND THE BUS BAR
OR WIRE WRAP OR WITHIN

MOLDER HARDWARE, FASTON TABS ALONG THE

IDEAL FOR THIN EDGE WITH FORMS FOR
MATERIALS AND HIGH EASY ACCESS
TORQUE APPLICATIONS

MULTILAYER AND MULTI- FLANGE TAB

CONDUCTOR TABS FOR CONSTRUCTION WITH
PCB POWER CLINCH HARDWARE

RING LUG TERMINATIONS SOLDER PIN CONNECTION

USING CLINCH STUD WITH THERMAL RELIEF
HARDWARE IN
FORMED TABS

SOLDER PINS FOR CONNECTORS IN PLASTIC

PCB CONNECTION WITH HOUSING, SOLDERED INTO
THERMAL RELIEF HOLES EACH CONDUCTOR
IN BUS BAR

CLINCH STUD FLEX CIRCUIT

HARDWARE IN SIDE TAB INTEGRATED INTO BUS
INTERCONNECT (NOTE BAR FOR FLEXIBLE
OFFSET FORM IN TAB) INTERCONNECTION

HIGH CURRENT POWER THREE-LAYER BUS BAR

RECEPTACLE WITH UTILIZING EMBOSSED
CROWN-BAND INSERTS “DIMPLES” FOR COPLANAR
INTERCONNECTION

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Bus Bar 39

A GLOBAL PLAYER
A global expert in materials
and solutions for extreme
environments as well as in
the safety and reliability
of electrical equipment,
Mersen designs innovative
solutions to address its
MERSEN Rochester MERSEN France
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A WORLD LEADER
in safety & reliability
for electrical power
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their manufacturing process
in sectors such as energy,
transportation, electronics,
chemical, pharmaceutical,
and process industries.
MERSEN Shanghai
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