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Bus Bar Advantages

What Is a Laminated Bus Bar?

A laminated bus bar is an engineered component consisting of layers of fabricated copper separated by thin dielectric materials, laminated into a unified structure. Sizes and applications range from surface-mounted bus bars the size of a fingertip to multilayer bus bars that exceed 20 feet in length. Laminated bus bar solutions are routinely used for low volumes up through tens of thousands per week.

Why Choose a Laminated Bus Bar?

Bus bars reduce system costs, improve reliability, increase capacitance, and eliminate wiring errors. They also lower inductance and increase capacitance. Plus, the physical structure of bus bars offers unique features in mechanical design. For example, complete power distribution subsystems can also act as structural members of a total system. Multilayer bus bars offer a structural integrity that wiring methods just can’t match.

Bus Bars Reduce System Costs
A laminated bus bar will lower manufacturing costs by decreasing assembly time as well as internal material handling costs. Various conductors are terminated at customer specified locations to eliminate the guesswork usually associated with assembly operating procedures. A reduced parts count will reduce ordering, material handling and inventory costs.
Bus Bars Fabrication Allows Flexibility
Fabricated bus bars fit your specific needs and are customized for maximum efficiency.
Bus Bars Improve Reliability
Laminated bus bars can help your organization build quality into processes. The reduction of wiring errors results in fewer reworks, lower service costs and lower quality costs.
Laminated Bus Bars Increase Capacitance
Increased capacitance results in decreasing characteristic impedance. This will ultimately lead to greater effective signal suppression and noise elimination. Keeping the dielectrics thin and using dielectrics with a high relative K factor will increase capacitance.
Eliminate Wiring Errors
By replacing a standard cable harnesses with bus bars, the possibility for miss-wirings is eliminated. Wiring harnesses have high failure rates relative to bus bars, which have virtually none. These problems are very costly to repair. Adding bus bars to your systems is effective insurance.
Bus Bars Lower Inductance
Any conductor carrying current will develop an electromagnetic field. The use of thin parallel conductors with a thin dielectric laminated together minimizes the effect of inductance on electrical circuits. Magnetic flux cancellation is maximized when opposing potentials are laminated together. Laminated bus bars have been designed to reduce the proximity effect in many semiconductor applications as well as applications that involve high electromagnetic interference (EMI) such as SiC or GaN high frequency circuits.
Bus Bars Lower Impedance
Increasing the capacitance and reducing the inductance is a determining factor in eliminating noise. Keeping the dielectric thickness to a minimum will accomplish the highly desired low impedance.
Bus Bars Provide Denser Packaging
The use of wide, thin conductors laminated together led to decreased space requirements. Laminated bus bars have helped decrease total system size and cost.
Bus Bars Provide Wider Variety of Interconnection Methods
The flexibility of bus bars have allowed an unlimited number of interconnection styles to choose from. Bushings, embossments, and faston® tabs are most commonly used. Wire harnesses, solderable connectors, and pressed-in fittings are also integrated into the design, making a bus bar compatible with virtually any type of interface.
Bus Bars Improve Thermal Characteristics
The wide, thin conductors are favorable to allowing better airflow in systems. As package sizes decrease, the cost of removing heat from systems is greatly increased. A bus bar not only reduces the overall size of system package required, but it can also improve airflow with its sleek design.


The electrical performance of an MERSEN- engineered laminated bus bar is a key component of success throughout the transportation industry. Mersen laminated bus bars help transportation equipment manufacturers achieve their reliability goals, thus lowering warranty costs and enhancing customer satisfaction.


Whether it is carrying the high current necessary to power heavy equipment, rail and subway cars, or reducing weight and enhancing packaging efficiency for 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 an 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 balance and distributed capacitance. MERSEN laminated bus bars help transportation equipment manufacturers achieve their reliability goals, thus lowering warranty costs and enhancing customer satisfaction.



The laminated bus bar shown here represents a single-phase leg for a large three-phase inverter powering modern AC locomotives. Long term durability and continuous operation in hostile environments demand high quality and consistency. The laminated bus bar has mold-sealed edges and fully insulated mounting holes, built and tested to meet customer partial discharge requirements.

: 10” x 14” x 30”
: .030”
: 1200VDC
: 1000A
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