Methods and apparatus for optimizing structural layout of multi-circuit laminated composite assembly

• US 8,785,784 B1
• Filed: 03/13/2013
• Issued: 07/22/2014
• Est. Priority Date: 03/13/2013
• Status: Active Grant

• Current Assignee: BWP Group
• Original Assignee: Boulder Wind Power, Inc.
• Inventors: Duford, James D., Jore, James D., Jore, Lincoln M., Smith, James S.
• Primary Examiner(s): Patel, Ishwarbhai B
• Application Number:
  US13/799,998
• Time in Patent Office: 496 Days
• Field of Search: None
• US Class Current: 174/255
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H05K 1/0256 Electrical insulation details, e.g. around high voltage areas
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/0191 wherein the thickness of the dielectric plays an important role

Abstract

A laminated composite assembly includes a layer having a first conductor with a first side and a second side. A first electric insulator is disposed between the first side of the first conductor and a second conductor such that a difference between a voltage associated with the first conductor and a voltage associated with the second conductor defines a voltage stress therebetween. The first electric insulator providing a first degree of electrical isolation based on the voltage stress. A second electric insulator is disposed between the second side of the first conductor and a third conductor such that a difference between the voltage associated with the first conductor and a voltage associated with the third conductor defines a second voltage stress therebetween. The second electric insulator providing a second degree of electrical isolation based on the second voltage stress.

Claims

1. An apparatus, comprising:

a layer of a laminated composite assembly, the layer having a first conductor, the first conductor having a first side and a second side disposed opposite the first side;

a first electric insulator disposed between the first side of the first conductor and a second conductor electrically coupled to the first conductor such that a voltage associated with the first conductor is substantially equal to a voltage associated with the second conductor, the first electric insulator providing a first degree of electrical isolation between the first conductor and the second conductor, the first electric insulator being selected to achieve the first degree of electrical isolation based on a voltage stress between the first conductor and the second conductor; and

a second electric insulator disposed between the second side of the first conductor and a third conductor electrically isolated within the laminated composite assembly from the first conductor and the second conductor, the third conductor associated with a voltage substantially different than the voltage associated with the first conductor such that a difference between the voltage associated with the first conductor and the voltage associated with the third conductor defines a voltage stress between the first conductor and the third conductor, the second electric insulator providing a second degree of electrical isolation between the first conductor and the third conductor, the second electric insulator being selected to achieve the second degree of electrical isolation based on the voltage stress between the first conductor and the third conductor, the second degree of electrical isolation being different than the first degree of electrical isolation.

2. The apparatus of claim 1, wherein the first electric insulator has a first thickness, the second electric insulator has a second thickness different from the first thickness, the first degree of electrical isolation being based at least in part on the first thickness, the second degree of electrical isolation being based at least in part on the second thickness.

3. The apparatus of claim 1, wherein the first electric insulator has a first dielectric strength, the second electric insulator has a second dielectric strength different from the first dielectric strength, the first degree of electrical isolation being based at least in part on the first dielectric strength, the second degree of electrical isolation being based at least in part on the second dielectric strength.

4. The apparatus of claim 1, wherein the first conductor includes at least one of an end turn of a machine coil, a power distribution conductor or an internal machine coil interconnection.

5. The apparatus of claim 1, wherein the voltage stress between the first conductor and the third conductor is associated with an electrical phase-to-phase voltage of a multi-phase machine winding.

6. The apparatus of claim 1, wherein the first conductor is an internal bus bar that electrically couples a first machine coil having the voltage associated with the first conductor with a second machine coil having the voltage associated with the first conductor.

7. The apparatus of claim 1, wherein the first conductor includes a plurality of non-intersecting electrical paths.

8. The apparatus of claim 1, wherein at least one of the second conductor and the third conductor are part of a mechanical structure configured to substantially retain the laminated composite assembly.

9. An apparatus, comprising:

a laminated composite assembly having a first plurality of layers and a second plurality of layers, each layer from the first plurality of layers having a conductor electrically coupled to a conductor of each remaining layer from the first plurality of layers to define a first electrical circuit, associated with a first voltage, each layer from the second plurality of layers having a conductor electrically coupled to a conductor of each remaining layer from the second plurality of layers to define a second electrical circuit (1) electrically isolated within the laminated composite assembly from the first electrical circuit and (2) associated with a second voltage different from the first voltage,

the laminated composite assembly having a first electric insulator that provides a first degree of electrical isolation between the conductor of a first layer from the first plurality of layers and the conductor of a second layer from the first plurality of layers, the first degree of electrical isolation associated with the first voltage, the laminated composite assembly having a second electric insulator that provides a second degree of electrical isolation, different from the first degree of electrical isolation, between the conductor of a third layer from the first plurality of layers and the conductor of a layer from the second plurality of layers, the second degree of electrical isolation associated with a difference between the first voltage and the second voltage.

10. The apparatus of claim 9, wherein the first electric insulator has a first thickness, the second electric insulator has a second thickness different from the first thickness, the first degree of electrical isolation being based at least in part on the first thickness, the second degree of electrical isolation being based at least in part on the second thickness.

11. The apparatus of claim 9, wherein the first electric insulator has a first dielectric strength, the second electric insulator has a second dielectric strength different from the first dielectric strength, the first degree of electrical isolation being based at least in part on the first dielectric strength, the second degree of electrical isolation being based at least in part on the second dielectric strength.

12. The apparatus of claim 9, wherein the conductor of the first layer from the first plurality of layers includes at least one of an end turn of a machine coil, a power distribution conductor or an internal machine coil interconnection.

13. The apparatus of claim 9, wherein the first electrical circuit and the second electrical circuit are associated with different phases of a multi-phase machine winding.

14. The apparatus of claim 10, wherein the second thickness is greater than the first thickness.

15. The apparatus of claim 9, wherein the conductor of the first layer from the first plurality of layers is an internal bus bar that electrically couples a first machine coil associated with the first electrical circuit with a second machine coil associated with the first electrical circuit.

16. The apparatus of claim 9, wherein the conductor of the first layer from the first plurality of layers includes a plurality of non-intersecting electrical traces.

17. An apparatus, comprising:

a first machine coil associated with a first phase of a multi-phase set of machine windings, the first machine coil being at least one electrical path on a first layer of a laminated composite assembly;

a second machine coil associated with the first phase of the multi-phase set of machine windings, the second machine coil being (1) at least one electrical path on a second layer of the laminated composite assembly and (2) electrically connected to the first machine coil via an internal connection such that the second machine coil is associated with a voltage substantially similar to a voltage associated with the first machine coil, the internal connection being at least one electrical path on the laminated composite assembly;

a third machine coil associated with a second phase of the multi-phase set of machine windings, the third machine coil being (1) at least one electrical path on a third layer of the laminated composite assembly and (2) electrically isolated within the laminated composite assembly from the first machine coil and the second machine coil, the third machine coil configured to be associated with a voltage different from the voltage associated with the first machine coil;

a first electric insulator disposed between the first layer and the second layer, the first electric insulator providing a first degree of electrical isolation based on a voltage stress between at least a portion of the first machine coil and at least a portion of the second machine coil; and

a second electric insulator disposed between the second layer and the third layer of the laminated composite assembly, the second electric insulator providing a second degree of electrical isolation based on a voltage stress between at least a portion of the second machine coil and at least a portion of the third machine coil, the second degree of electrical isolation being different from the first degree of electrical isolation, the laminated composite assembly forming at least a portion of a segment included in a segmented machine.

18. The apparatus of claim 17, wherein the internal connection electrically couples the first machine coil and the second machine coil in an electrically parallel configuration.

19. The apparatus of claim 17, wherein the internal connection is at least one of an electrical trace on a layer of the laminated composite assembly or an electrical via electrically coupling a plurality of layers of the laminated composite assembly.

20. The apparatus of claim 17, wherein the internal connection is arranged to electrically couple the first machine coil and the second machine coil in an electrically series configuration.

21. The apparatus of claim 17, wherein the internal connection includes a plurality of parallel electrical paths.

22. The apparatus of claim 17, wherein the internal connection is a first internal connection, the apparatus further comprising:

a fourth machine coil configured to be associated with the second phase of the multi-phase set of machine windings, the fourth machine coil being (1) at least one electrical path on a fourth layer of the laminated composite assembly and (2) electrically connected to the third machine winding via a second internal connection such that the fourth machine coil is configured to be associated with a voltage substantially similar to the voltage associated with the third machine coil, the second internal connection being at least one electrical path on the laminated composite assembly.