High-density, high-temperature resistant busbars are available from suppliers like Mersen, Rogers (ROLINX), Molex, RHI, and Exxelia, with temperature ratings up to 1000℃ and compact, laminated designs for high-current applications.

Key Suppliers and Products

Mersen MHi-T™ Bus Bars Mersen offers high-temperature busbars designed for Wide Band Gap (WBG) power modules, capable of withstanding working temperatures up to 130°C and 180°C. They use polyaramid dielectric insulation and high-temperature adhesives to maintain structural integrity and prevent insulation breakdown under high thermal stress, making them suitable for SiC- and GaN-based power electronics applications . Rogers ROLINX® Laminated Busbars ROLINX busbars are laminated copper or aluminum layers separated by dielectric materials, engineered for high power density and low inductance. They are widely used in EV/HEV, rail, renewable energy, and industrial drives, offering compact, high-current solutions with excellent thermal and electrical performance . Molex Busbars Molex provides rigid, flexible, and laminated busbars with high-current capacity and thermal stability. Their busbars are designed for high-power, high-density, and elevated-temperature environments, with options for copper or aluminum conductors, multiple insulation types, and plating finishes. Molex also supports customized designs and liquid-cooled solutions for advanced thermal management . RHI High-Temperature Busbars RHI specializes in busbars with mica tape, ceramic composite tape, and ceramic-enhanced silicone rubber coatings, capable of withstanding extreme temperatures up to 1000℃. These busbars are suitable for new energy systems requiring high current and robust insulation . Exxelia SVM Laminated Busbars Exxelia offers laminated busbars with multiple copper layers and high-performance insulation (FR4, G10, flame glass UL 94 V-0), designed for high-current, high-density applications in power electronics, renewable energy, aerospace, and automotive sectors. Their busbars provide compact designs, enhanced thermal performance, and reliability in demanding environments .

Considerations for Selection

• Temperature Rating: Choose busbars rated for the maximum operating temperature of your system (up to 1000℃ for extreme cases).
• Material: Copper is preferred for high conductivity; aluminum may be used for weight-sensitive applications.
• Insulation: Options include mica, ceramic composites, polyaramid, and silicone-based coatings for high-temperature resistance.
• Form Factor: Laminated busbars reduce inductance and improve thermal management, while flexible busbars allow vibration tolerance and easier routing.
• Customization: Many suppliers offer tailored solutions for specific current ratings, geometries, and integration with connectors or cooling systems. These suppliers provide in-stock and customizable high-density, high-temperature busbars suitable for demanding industrial, automotive, and renewable energy applications.