LOW INDUCTANCE BUSBAR SYSTEMS AND METHODS

• US 20180123334A1
• Filed: 10/27/2016
• Published: 05/03/2018
• Est. Priority Date: 10/27/2016
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: She, Xu, Datta, Rajib, Raju, Ravisekhar Nadimpalli, Harfman-Todorovic, Maja, Cioffi, Philip Michael
• Granted Patent: US 10,103,534 B2
• Time in Patent Office: Days
• CPC Class Codes: H01G 2/02 Mountings
• CPC Class Codes: H01G 4/228 Terminals
• CPC Class Codes: H01G 4/38 Multiple capacitors, i.e. structural combinations of fixed capacitors
• CPC Class Codes: H01G 9/008 Terminals
• CPC Class Codes: H01G 9/26 Structural combinations of electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices with each other
• CPC Class Codes: H02B 1/20 Bus-bar or other wiring layouts, e.g. in cubicles, in switchyards installations of bus-bars H02G5/00
• CPC Class Codes: H02G 5/00 Installations of bus-bars
• CPC Class Codes: H02G 5/005 Laminated bus-bars
• CPC Class Codes: H02G 5/007 Butt joining of bus-bars by means of a common bolt, e.g. splice joint electrically conductive connections characterised by contacting members H01R4/58
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/02 Arrangements of circuit components or wiring on supporting structure
• CPC Class Codes: H05K 7/14329 specially adapted for the configuration of power bus bars

Abstract

An electrical system includes a power electronics system and a bus bar coupled to the power electronic system. The power electronics system includes a switching device configured to selectively connect and disconnect. The bus bar includes a first conductive layer and a second conductive layer. The first conductive layer is disposed directly adjacent a first insulation layer, wherein the first conductive layer is configured to conduct a first polarity of electrical power to, from, or both the power electronics system. The second conductive layer is disposed directly adjacent the first insulation layer, and is configured to conduct a second polarity of electrical power opposite the first polarity to, from, or both the power electronics system. The first conductive layer comprises a first thickness half a second thickness of the second conductive layer.

Claims

1. An electrical system, comprising:

a power electronics system comprising a switching device, wherein the switching device is configured to selectively connect and disconnect;

a bus bar electrically coupled to the power electronics system, wherein the bus bar comprises;

a first conductive layer disposed directly adjacent a first insulation layer, wherein the first conductive layer is configured to conduct a first polarity of electrical power to, from, or both the power electronics system; and

a second conductive layer disposed directly adjacent the first insulation layer, wherein the second configured to conduct a second polarity of electrical power opposite the first polarity to, from, or both the power electronics system;

wherein the first conductive layer comprises a first thickness half a second thickness of the second conductive layer.

2. The electrical system of claim 1, wherein the bus bar comprises a third conductive layer disposed directly adjacent a second insulation film, wherein:

the third conductive layer is configured to conduct the first polarity of electrical power to, from, or both the power electronics system in parallel with the first conductive layer; and

the third conductive layer comprises the second thickness.

3. The electrical system of claim 2, wherein the bus bar comprises:

a fourth conductive layer disposed directly adjacent a third insulation layer and directly adjacent a fourth insulation layer disposed directly adjacent the second conductive layer, wherein;

the fourth conductive layer is configured to conduct the first polarity of electrical power to, from, or both the power electronics system in parallel with the first conductive layer and the third conductive layer; and

the fourth conductive layer comprises the second thickness; and

a fifth conductive layer disposed directly adjacent the second insulation layer and directly adjacent the third insulation layer, wherein;

the fifth conductive layer is configured to conduct the second polarity of electrical power to, from, or both the power electronics system in parallel with the second conductive layer; and

the fifth conductive layer comprises the first thickness.

4. The electrical system of claim 2, wherein the second conductive layer is disposed directly adjacent the second insulation layer.

5. The electrical system of claim 1, comprising a capacitor coupled to an exterior surface of the bus bar, wherein the capacitor comprises:

a first terminal electrically connected to the first conductive layer; and

a second terminal electrically connected to the second conductive layer.

6. The electrical system of claim 5, comprising:

a first fastener that extends through the bus bar to;

secure the capacitor to the exterior surface of the bus bar;

electrically connecting the first terminal to the first conductive layer; and

electrically isolate the first terminal from the second conductive layer; and

a second fastener that extends through the bus bar to;

secure the capacitor to the exterior surface of the bus bar;

electrically connecting the second terminal to the second conductive layer; and

electrically isolate the first terminal from the first conductive layer.

7. The electrical system of claim 1, wherein the first insulation layer comprises a third thickness.

8. The electrical system of claim 1, wherein the bus bar is configured to:

enable the power electronics system to supply electrical power to an electrical load;

enable the power electronics system to receive electrical power from a power source;

or

both.

9. The electrical system of claim 1, wherein the power electronics system is configured to selectively connect and disconnect the switching device to facilitate converting input electrical power into output electrical power.

10. The electrical system of claim 1, wherein the electrical system comprises an industrial system, a manufacturing system, an automation system, a computing system, an automotive system, or any combination thereof.

11. A bus bar configured to electrically connect one or more electrical components, comprising:

an interior layer;

a first intermediate layer and a second intermediate layer electrically connected in parallel and disposed on opposite sides of the interior layer;

a first exterior layer electrically connected in parallel with the interior layer, wherein the first exterior layer and the interior layer are disposed on opposite sides of the first intermediate layer; and

a second exterior layer electrically connected in parallel with the interior layer and the first exterior layer, wherein the second exterior layer and the interior layer are disposed on opposite sides of the second intermediate layer;

wherein volume of the interior layer is different from volume of the first exterior layer and volume of the second exterior layer.

12. The bus bar of claim 11, wherein volume of the interior layer is equal to a sum of voltage of the first volume of the first exterior layer and volume of the second exterior layer.

13. The bus bar of claim 11, comprising a first terminal fastener extending through the bus bar and connecting to a first terminal of one of one or more capacitors, wherein the first terminal fastener contacts the interior layer and the exterior layers, connecting them in parallel, but does not contact the intermediate layers.

14. The bus bar of claim 13, comprising a second terminal fastener extending through the bus bar and connecting to a second terminal of one of the one or more capacitors, wherein the second terminal fastener contacts the intermediate layers, connecting them in parallel, but does not contact the interior layer and the exterior layers.

15. The bus bar of claim 11, wherein the bus bar is symmetrical about a plane extending through the interior layer and parallel to the first intermediate layer and the second intermediate layer.

16. A method of manufacturing a bus bar used to electrically connect one or more electrical components, comprising:

coupling a first insulating layer to a first side of an interior layer, wherein the interior layer comprises a first thickness;

coupling a second insulating layer to a second side of the interior layer;

coupling a first intermediate layer to the second insulating layer, wherein the first intermediate layer comprises the first thickness;

coupling a second intermediate layer to the first insulating layer, wherein the second intermediate layer comprises the first thickness;

coupling a third insulating layer to the first intermediate layer;

coupling a fourth insulating layer to the second intermediate layer;

coupling a first external layer to the third insulating layer, wherein the first external layer comprises a second thickness different from the first thickness; and

coupling a second external layer to the fourth insulating layer, wherein the second external layer comprises the second thickness.

17. The method of claim 16, wherein the first thickness is twice the second thickness.

18. The method of claim 16, comprising:

electrically connecting the interior layer, the first external layer, and the second external layer in parallel; and

electrically connecting the first intermediate layer and the second intermediate layer in parallel.

19. The method of claim 16, comprising:

forming a first hole through the bus bar to facilitate securing a capacitor to the bus bar and electrically connecting a first terminal of the capacitor to the interior layer, the first external layer, and the second external layer; and

forming a second hole the bus bar to facilitate securing the capacitor to the bus bar and electrically connecting a second terminal of the capacitor to the first intermediate layer and the second intermediate layer.

20. The method of claim 16, wherein:

forming the first hole comprises;

forming the first hole with a first diameter in the interior layer, the first external layer, and the second external layer; and

forming the first hole with a second diameter greater than the first diameter in the first intermediate layer and the second intermediate layer; and

forming the second hole comprises;

forming the second hole with the second diameter in the interior layer, the first external layer, and the second external layer; and

forming the second hole with first diameter in the first intermediate layer and the second intermediate layer.