Low impedance contoured laminated bus assembly and method for making same
First Claim
1. A low impedance laminated bus assembly for use with a motor inverter that has a plurality of switch pairs, each of the plurality of switch pairs including a -DC switch and a +DC switch for high speed switching to convert between DC power from a DC energy storage unit that has a +DC line side and a -DC line side to AC power on a plurality of AC power lines, said laminated bus assembly comprising:
- a plurality of AC bus conductors including an AC bus conductor for each phase of AC power, each of said plurality of AC bus conductors including a main body portion positioned in a first conductor plane, a second body portion positioned in a second conductor plane nonparallel with said first conductor plane and a third body portion positioned in a third conductor plane nonparallel with said first conductor plane;
a -DC bus conductor connected to said -DC line side of the DC energy storage unit, the -DC bus conductor including a main body portion positioned in a fourth conductor plane substantially parallel to said first conductor plane and a second body portion positioned in a fifth conductor plane substantially parallel to said second conductor plane;
a +DC bus conductor connected to said +DC line side of the DC energy storage unit, the +DC bus conductor including a main body portion positioned in said fourth conductor plane and a second body portion positioned in a sixth conductor plane substantially parallel to said third conductor plane;
a midpoint bus conductor positioned in a seventh conductor plane substantially parallel to said first and fourth conductor planes;
a first dielectric layer laminated between said first conductor plane and said seventh conductor plane; and
,a second dielectric layer laminated between i) said first conductor plane and said fourth conductor plane, ii) said second conductor plane and said fifth conductor plane, and iii) said third conductor plane and said sixth conductor plane.
1 Assignment
0 Petitions
Accused Products
Abstract
A curved low impedance laminated bus assembly includes a curved first sheet of relatively thin conductive material forming an AC bus conductor and a curved second sheet of relatively thin conductive material forming a -DC bus conductor directly connected to a -DC line side of a DC energy storage device. A curved third sheet of relatively thin conductive material forms a +DC bus conductor directly connected to a +DC line side of the DC energy storage device and is connected to the AC bus conductor through a +DC switch. A plurality of dielectric sheets are laminated between the AC bus conductor, the -DC bus conductor, and the +DC bus conductor. A method of making the low impedance laminated bus assembly includes providing a first substantially planar sheet of relatively thin conductive material forming an AC bus conductor, providing a second substantially planar sheet of relatively thin conductive material forming a -DC bus conductor, providing a third substantially planar sheet of relatively thin conductive material forming a +DC bus conductor, providing plurality of dielectric sheets, stacking said plurality of dielectric sheets between said AC bus conductor, said -DC bus conductor, and said +DC bus conductor to form a laminated bus structure having alternating conductive and non-conductive layers. Lastly, the laminated bus structure is bent from a first substantially planar shape to a second curved shape.
62 Citations
19 Claims
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1. A low impedance laminated bus assembly for use with a motor inverter that has a plurality of switch pairs, each of the plurality of switch pairs including a -DC switch and a +DC switch for high speed switching to convert between DC power from a DC energy storage unit that has a +DC line side and a -DC line side to AC power on a plurality of AC power lines, said laminated bus assembly comprising:
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a plurality of AC bus conductors including an AC bus conductor for each phase of AC power, each of said plurality of AC bus conductors including a main body portion positioned in a first conductor plane, a second body portion positioned in a second conductor plane nonparallel with said first conductor plane and a third body portion positioned in a third conductor plane nonparallel with said first conductor plane; a -DC bus conductor connected to said -DC line side of the DC energy storage unit, the -DC bus conductor including a main body portion positioned in a fourth conductor plane substantially parallel to said first conductor plane and a second body portion positioned in a fifth conductor plane substantially parallel to said second conductor plane; a +DC bus conductor connected to said +DC line side of the DC energy storage unit, the +DC bus conductor including a main body portion positioned in said fourth conductor plane and a second body portion positioned in a sixth conductor plane substantially parallel to said third conductor plane; a midpoint bus conductor positioned in a seventh conductor plane substantially parallel to said first and fourth conductor planes; a first dielectric layer laminated between said first conductor plane and said seventh conductor plane; and
,a second dielectric layer laminated between i) said first conductor plane and said fourth conductor plane, ii) said second conductor plane and said fifth conductor plane, and iii) said third conductor plane and said sixth conductor plane. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A curved low impedance laminated bus assembly for use with a power converter having a switch pair including a -DC switch and a +DC switch for switching to convert between DC power from a DC energy storage device that has a +DC line side and a -DC line side to AC power on an AC power line, said laminated bus assembly comprising:
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a curved first sheet of relatively thin conductive material forming an AC bus conductor; a curved second sheet of relatively thin conductive material forming a -DC bus conductor directly connected to said -DC line side of said DC energy storage device and connected to said AC bus conductor through said -DC switch; a curved third sheet of relatively thin conductive material forming a +DC bus conductor directly connected to said +DC line side of said DC energy storage device and connected to said AC bus conductor through said +DC switch; and
,a plurality of dielectric sheets laminated between said AC bus conductor, said -DC bus conductor, and said +DC bus conductor. - View Dependent Claims (14, 15, 16, 17)
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18. A method of making a low impedance laminated bus assembly for use with a power converter having a switch pair including a -DC switch and a +DC switch for switching to convert between DC power from a DC energy storage device that has a +DC line side and a -DC line side to AC power on an AC power line, the method comprising the steps of:
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providing a first substantially planar sheet of relatively thin conductive material forming an AC bus conductor; providing a second substantially planar sheet of relatively thin conductive material forming a -DC bus conductor adapted for direct connection to said -DC line side of said DC energy storage device and for connection to said AC bus conductor through said -DC switch; providing a third substantially planar sheet of relatively thin conductive material forming a +DC bus conductor adapted for direct connection to said +DC line side of said DC energy storage device and for connection to said AC bus conductor through said +DC switch; providing plurality of dielectric sheets; stacking said plurality of dielectric sheets between said AC bus conductor, said -DC bus conductor, and said +DC bus conductor to form a laminated bus structure having alternating conductive and non-conductive layers; and
,bending the laminated bus structure from a first substantially planar shape to a second curved shape. - View Dependent Claims (19)
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Specification