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A g lo b a l r e p u tat i o n f o r q u a l i t yMersen is a global expert in electrical power andadvanced materials. Mersen designs innovativesolutions to address its clients specific needs toenable them to optimize their manufacturing processacross numerous industrial sectors.l e v e r ag i n g ov e r 6 5 y e a r sof experienceA REPUTATION FOR Q UALITYMersen’s reputation for outstanding technicalexpertise, product quality, and engineered safetyis the result of over a century of design andmanufacturing knowledge, coupled with state-ofthe-art equipment in three ISO-9001 registeredfacilities. Each facility manufactures single andmultilayer bus bars, as well as fully integratedWith the addition of Eldre in USA and France to thesolutions in which the laminated bus bar alsoMersen family in 2012, Mersen added laminated busserves as a platform for a multitude of discreetbars to its extensive portfolio of products. Alongcomponents:with other solutions for power management suchas cooling and fuses, Mersen has created a powerful In Europe, our 5,000 m2 plant in Angers, Francebundled product offering for the protection andis a center of excellence for laminated bus barmanagement of power electronics.solutions.Angers isIRIS certifiedW H AT IS LAMINATED BUS BAR ?to betterLaminated bus bar is an engineered componentserve the railconsisting of layers of fabricated copper separatedindustry.by thin dielectric materials, laminated into a unifiedstructure. Sizes and applications range from surface Rochester, New York is a vertically integrateda fingertip tosolutions,in length. Laminatedand isbus bar solutionsregisteredfor low volumesand ITARup through tens ofCertified.thousands per week.increase capacitance, and eliminate wiring errors.They also lower inductance and lower impedance.Plus, the physical structure of bus bars offers uniquefeatures in mechanical design. Multilayer bus barsITARAS9100Care routinely usedBus bars reduce system costs, improve reliability,s RegulatArmindistributionthat exceed 20 feetnal Trafficatiornd with Inereteistcenter of excellence for all powermultilayer bus barsW H Y C H OOSE LAMINATEDBUS BAR ?In North America, our 110,000 ft2 plant inRegbars the size ofsionmounted bus In Asia, a brand-new 6,500 m2 facility inShanghai, China offers full manufacturingcapabilityof all powerand bus barsolutions.offer a structural integrity that wiring methods justcan’t match.2 Mersen Laminated Bus Bar Solutionse p. m e r s e n . c o mb u s ba r .co m

OUR VALUE P RO P OSITON : P IECE OF MINDSUPERIOR Q UALITY FROMDESIGN T H ROUG H MANUFACTUREmonitoring, in-process controls, and x-ray testingFrom the first design consultation through dock-to-Precision manufacturing of dielectriccombine to ensure a quality finish.components is crucial in laminated bus barstock shipments, Mersen provides customers withproduction. To ensure quality, we maintaininnovative power distribution solutions. You’re alwayscalibrated humidity and temperature controlledassured that we’ve omitted nothing in our quest forconditions to store our insulation. Precision steelcustomer satisfaction. Let us offer you the same peacerule dies are used for cutting the insulation,of mind that thousands of other companies haveensuring uniformity of size to produce qualityenjoyed for more than 60 years. Here are just a fewbus bars.reasons: State-of-the-art metal fabrication is a key a bus bar’s electrical integrity. We utilize a widecomponent to producing quality product. Ourvariety of dielectric materials, including Nomex,state-of-the-art metal fabrication is maintainedTedlar, Mylar, Kapton, Epoxy-Glass, GPO, Gatex,in-house and includes CNC fabricators, photo-and Phenolics; readily available to meet virtuallychemical machining, production punch pressesany specification. In addition to traditionalranging up to 200 tons, CNC press brakes, andsheet lamination systems, we maintain ourvarious edge conditioning processes. We offer aown electrostatic powder coating departmentwide range of metal joining processes includingthat produces a quality epoxy finish with highultrasonic welding, induction brazing, torchdielectric protection for bus bars with geometricbrazing, and soldering. Plating – Our complete, in-house platingdepartment can produce almost any finish to meetyour needs. Our finishing includes tin, tin-lead,nickel, copper, silver, and gold. Plating under tight,laboratory-controlled conditions, we monitor andcontrol plating thickness to required specificationsto meet all customer requirements. Careful datae p. m e r s e n . c o mb u s ba r .co mProperly selected insulation is the key factor toforms, or those used in harsh environments. Assembly and Lamination is controlled usingsophisticated laminating systems specificallydesigned and manufactured for each bus bar.Hardware and interconnection devices can beadded before or after the laminating and platingprocess.Mersen Laminated Bus Bar Solutions 3

BUS BARS BUILT FOR THE REAL WORLDQ UALITY AND PERFORMANCEF O R VA R I O U S M A R K E T SMersen has a keen understanding of the uniquePower Electronics/Silicon CarbideApplicationsPages 6-7challenges customers face in each of the marketswe serve. We deliver extensive product expertiseand unbeatable applications support, enabling ourcustomers to optimize their market performance.We are experts in designing, simulating,industrialPages 8-9manufacturing, and testing bus bar solutions toserve AC and DC power electronics applicationswhere Wide Band Gap (SiC, GaN) and Silicon(IGBT, Thyristors) technologies are used for powerconversion and battery-related applications. Wecater to the unique needs of many markets andDEFENSE andaerospacepages 10-11applications.STRAIG H T TO T H EOPTIMUM DESIGNtransportationpages 12-13Mersen engineers can work with invertermanufacturers at very early stages of design tointegrate the passive components such as cooling,busbars and fuses within the inverter. Using avariety of Multiphysics simulation toolsets, Mersenengineers can evaluate the thermal and electricalEV/HEV andEnergy StoragePages 14-15performance of the heat sinks and bus bars withinthe overall inverter design. This approach is calledthe Integrated Architecture approach and allowsfor the most optimum design footprint of theoverall inverter assembly by sourcing the coolingand bus bar solutions along with semiconductorrenewableenergypage 16protection fuses all from one source. For moreinformation on cooling andfuses, please s 17-21value-addassembliespage 224 Mersen Laminated Bus Bar Solutionse p. m e r s e n . c o mb u s ba r .co m

ENGINEERING SU P P ORT AND TESTING FOR EACH DESIGNMULTIP H YSICS MODELLINGBuilding a prototype is simply time consuming, dueto the number of various specialized operationsinvolved, and can sometimes be incompatiblewith the client deadline. Once the prototype hasbeen finalized, running the test itself is not so easy,especially as the worst case scenario has to beinvestigated. High temperature, complex or highcurrent electrical client conditions might not beaddition to dielectric withstanding, or insulationbreakdown testing (aka “HiPot”), Mersen performsPartial Discharge testing using the state ofthe art Hipotronics PD test station. Mersen’sengineering and quality team uses DFM (DesignFor Manufacturability) techniques such as FMEA(Failure Mode Analysis) to evaluate each order toassure smooth transition without failures throughoutthe process.easy to recreate.Oversized constructions do not fit in a typicalenvironmental chamber. The test can thereforeturn out expensive and add unnecessary studytime. That’s why simulation is a handy tool to boostdevelopment processes.By adding pre-test steps in the conception phase,design flaws can be spotted and eliminated beforegoing through the prototype manufacturingprocess. Overheating areas or overly thick plates arenot always clear to determine by calculations.T H ERMAL AND ELECTRICALSIMULATIONSMersen application engineers can conducttemperature rise simulation on the bus barprototypes. This will ensure the most thermalefficient busbar design will go to production,providing our customers optimum productperformance and lowest heat dissipation. In additioncan also be subjected to electrical current flowW E CAN H ELP YOU W IT H ANYDESIGNS OR SPECIFICATIONSsimulations, inductance values and skin effectWe at Mersen provide FREE consultation for ourcalculations. Mersen has perfected pre-design rulescustomers to be able to directly discuss theirover years of experience and can provide a verydesign requirements with our expert applicationefficient design from the get go.and product specialists. We take pride in strivingto temperature rise simulations, prototype piecesto provide fast response time, usually within oneH I - P OT A N D PA R T I A LDISC H ARGE TESTINGRigorous testing is completed on each part priorto shipment to ensure long term reliability. Ine p. m e r s e n . c o mb u s ba r .co mbusiness day to customers enquiries. We provideone on one design and engineering support toarrive at the best fit solution every time. Visitep.mersen.com for contact information.Mersen Laminated Bus Bar Solutions 5

MAR K ETS SER V ED :P o w e r e l e c t r o n i c s a n d SILICON CARBIDE ( S i C ) A P P LICATIONSPower electronicsThe higher switching speed of today’s IGBT demands a low inductance power path which isuniquely delivered by the Mersen laminated bus bar. Mersen’s innovative Power Electronicdesigns provide the ultimate in low inductance DC power which is the “life blood,” securingthe best suppression of parasitic transients and safe operation for long life. The Mersenlaminated bus bar is the key component of the DC power circuit, enabling the IGBT /Electrolytic and Film Capacitor circuit to provide perfect power and trouble-free service.MOTOR DRIVE BUS BARThin copper conductors, separated by insulation material of only thousandthsof an inch, provides the ultimate in low inductance for IGBT-based motor drives.Incorporating electrolytic capacitors into the same structure simplifies packagingand reduces the effects of transient overshoots. Note the addition of SnubberCapacitors and Resistors built into the laminated bus bar!Size: 7" x 9" (25 mm x 228 mm) Thickness: .040" (1 mm) Voltage: 475VDC Current: 150ACAPACITOR BUS BAR FOR MOTOR DRIVESix electrolytic capacitors are easily connected to this edge-sealed, two-layerlaminated 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 thelength of the bus bar to provide additional “creepage” protection between theplus and minus terminals.Size: 1.8" x 6.3" (46 mm x 160 mm) Thickness: .040" (1 mm) Voltage: 480VDC Current: 60ACAPACITOR BUS BAR FOR MOTOR DRIVEA laminated bus bar assembly consisting of three power layers and one signallayer with a total of 59 conductors providing a very low inductance power pathand complete gate drive circuitry all designed for a wave-solder assembly process.This bus bar is used in a system powered by 24 MOSFETs. It includes ElectrolyticCapacitors, heatsinks, and MOVs.Size: 5" x 7" (127 mm x 178 mm) Conductors: .060" (1.5 mm) (gate circuit: .025"[.63 mm]) Voltage: 28VDC Current: 1000A peakMOUNTING STRUCTURE FOR CAPACITOR BANKLaminated bus bars provide a low inductance connection for capacitors. Theassembly was designed for an automated production process and the assembly isthe DC capacitor bank used in conjunction with high-current, high-speed switchingapplications. Positive and negative layers are formed and laminated without outsideinsulation. This design includes two rows of capacitors soldered into position.Length: 8" (203 mm) Width: 7.5" (190 mm) Voltage: 28V Current: 100A6 Mersen Laminated Bus Bar Solutionse p. m e r s e n . c o mb u s ba r .co m