MULTI-PHASE BUSBAR FOR CONDUCTING ELECTRIC ENERGY AND METHOD OF MANUFACTURING THE SAME

• US 20190305447A1
• Filed: 06/18/2019
• Published: 10/03/2019
• Est. Priority Date: 12/19/2016
• Status: Active Grant

• Current Assignee: ABB Schweiz AG (ABB Limited)
• Original Assignee: ABB Schweiz AG (ABB Limited)
• Inventors: Velthuis, Rudi, Krivda, Andrej
• Granted Patent: US 10,790,643 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: H01B 13/06 Insulating conductors or cables H01B13/32 takes precedence
• CPC Class Codes: H01B 7/009 Cables with built-in connecting points or with predetermined areas for making deviations
• CPC Class Codes: H01B 7/0216 Two layers
• CPC Class Codes: H01B 7/0225 Three or more layers
• CPC Class Codes: H01B 7/08 Flat or ribbon cables
• CPC Class Codes: H01R 9/2675 Electrical interconnections between two blocks, e.g. by means of busbars
• CPC Class Codes: H02B 1/056 Mounting on plugboards
• 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: H02B 1/21 Bus-bar arrangements for rack-mounted devices with withdrawable units
• CPC Class Codes: H02G 5/005 Laminated bus-bars
• CPC Class Codes: H05K 1/0256 Electrical insulation details, e.g. around high voltage areas
• CPC Class Codes: H05K 2201/0187 with regions of different dielectrics in the same layer, e.g. in a printed capacitor for locally changing the dielectric properties
• CPC Class Codes: H05K 2201/0191 wherein the thickness of the dielectric plays an important role
• CPC Class Codes: H05K 2201/10272 Busbars, i.e. thick metal bars mounted on the PCB as high-current conductors metal strips H05K2201/1028
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/4641 having integrally laminated metal sheets or special power cores
• CPC Class Codes: H05K 3/4647 : by applying an insulating layer around previously made via studs

Abstract

A multi-phase busbar for conducting electric energy includes: an insulating base layer made of an insulating material; a first conducting layer made of a sheet metal arranged on and adhesively bonded to the base layer; a first connecting pin mounted to the first conducting layer which extends in a direction with respect to the first conducting layer; a first insulating layer arranged on and adhesively bonded to the first conducting layer; a second conducting layer made of a sheet metal arranged on and adhesively bonded to the first insulating layer, the second conducting layer including a second connecting pin which extends in a direction parallel to the first connecting pin; and a second insulating layer arranged on and adhesively bonded to the second conducting layer. The second conducting layer and the first and second insulating layer each include at least one pinhole through which the first connecting pin projects.

Claims

1. A multi-phase busbar for conducting electric energy, comprising:

an insulating base layer comprising an insulating material;

a first conducting layer comprising a sheet metal which is arranged on and adhesively bonded to the base layer;

a first connecting pin mounted to the first conducting layer which extends in a direction with respect to the first conducting layer;

a first insulating layer arranged on and adhesively bonded to the first conducting layer;

a second conducting layer comprising a sheet metal which is arranged on and adhesively bonded to the first insulating layer, the second conducting layer comprising a second connecting pin which extends in a direction parallel to the first connecting pin; and

a second insulating layer arranged on and adhesively bonded to the second conducting layer,

wherein the second conducting layer and the first and second insulating layer each comprise at least one pinhole through which the first connecting pin projects, and wherein the first connecting pin is covered by a sleeve or cover of an insulating material which is arranged thereon and which projects from the first conducting layer through the pinholes formed in the second conducting layer and the insulating layers.

2. The multi-phase busbar according to claim 1, wherein the sleeve is clamped to the first connecting pin and/or is affixed to the first connecting pin by an adhesive, and/or

wherein the insulating sleeve comprises a shrinkable material comprising a thermoplastic resin which is shrunk to the first connecting pin.

3. The multi-phase busbar according to claim 1, further comprising a third conducting layer and a third insulating layer and a fourth conducting layer and a fourth insulating layer adhesively bonded to the second insulating layer, the third and fourth conducting layers and the third and fourth insulating layers comprising pinholes through which the first connecting pin and the sleeve project.

4. The multi-phase busbar according to claim 1, wherein at least one of the insulating layers includes a first insulating sub layer which is arranged on an upper side of a conducting layer and a second insulating sub layer which is arranged on a lower side of a conducting layer, the first insulating sub layer comprising a first pinhole having a diameter which is larger than the pinhole in the second conducting layer.

5. The multi-phase busbar according to claim 4, wherein the sleeve comprises a first collar of insulating material which is received in the first pinhole of the first insulating sub layer.

6. The multi-phase busbar according to claim 4, wherein at least one of the insulating layers includes a second insulating sub layer which is arranged on a lower side of a conducting layer, the second insulating sub layer comprising a second pinhole having a diameter which is smaller than the diameter of the pinhole in the second conducting layer.

7. The multi-phase busbar according to claim 6, further comprising at least one further sleeve mounted on the sleeve, the further sleeve comprising a first collar which is received in the pinhole of the second conducting layer, and/or having a further collar of insulating material which is received in the first pinhole of a first insulating sub layer.

8. The multi-phase busbar according to claim 1, wherein at least one conducting layer is coated by an electrically insulating material comprising an epoxy coating covering.

9. A method of manufacturing a multi-phase busbar according to claim 1, the method comprising the following method steps:

providing an insulating base layer made of an insulating material;

adhesively bonding a first conducting layer made of a sheet metal to the base layer, the first conducting layer comprising a first connecting pin mounted thereat which extends in a direction with respect to the first conducting layer;

mounting an insulating sleeve on the first connecting pin;

adhesively bonding a first insulating layer to the first conducting layer, the first insulating layer having a pinhole through which the first connecting pin and the sleeve project;

adhesively bonding a second conducting layer comprising a sheet metal to the first insulating layer, the second conducting layer comprising a second connecting pin which extends in a direction parallel to the first connecting pin and a pinhole through which the first connecting pin and the insulating sleeve project; and

adhesively bonding a second insulating layer on the second conducting layer, the second insulating layer comprising at least one pinhole through which the second connecting pin and the sleeve mounted thereto project.

10. The method of claim 9, wherein after adhesively bonding the first insulating layer to the first conducting layer, a second sleeve is mounted on the first sleeve and/or a further insulating sleeve is mounted on the second connecting pin.

11. The method of claim 10, wherein the second sleeve comprises a first collar, the first collar having a diameter which is smaller than the diameter of the first pinhole, and

wherein the first collar is inserted into the first pinhole of the second conducting layer when mounting the second sleeve on the first connecting pin.

12. A switchgear or switchgear cabinet, comprising:

the multi-phase busbar according to claim 1.

13. A method of manufacturing a multi-phase busbar according to claim 1, the method comprising the following method steps:

providing an insulating base layer comprising an insulating material;

placing a first conducting layer comprising a sheet metal to the base layer, the first conducting layer comprising a first connecting pin mounted thereat which extends in a direction perpendicular to the first conducting layer;

mounting an insulating sleeve on the first connecting pin;

placing a first insulating layer to the first conducting layer, the first insulating layer having a pinhole through which the first connecting pin and the sleeve project;

placing a second conducting layer comprising a sheet metal to the first insulating layer, the second conducting layer comprising a second connecting pin which extends in a direction parallel to the first connecting pin and a pinhole through which the first connecting pin and the insulating sleeve project;

placing a second insulating layer on the second conducting layer, the second insulating layer comprising at least one pinhole through which the second connecting pin and the sleeve mounted thereto; and

mechanically clamping together the insulating base layer and the second insulating layer.

14. The method of claim 13, wherein, after placing the first insulating layer to the first conducting layer, a second sleeve is mounted on the first sleeve and/or a further insulating sleeve is mounted on the second connecting pin.

15. The method of claim 14, wherein the second sleeve comprises a first collar, the first collar having a diameter which is smaller than the diameter of the first pinhole, and

wherein the first collar is inserted into the first pinhole of the second conducting layer when mounting the second sleeve on the first connecting pin.

16. The multi-phase busbar according to claim 1, wherein the direction in which the first conducting layer extends is perpendicular to the first conducting layer.

17. The method according to claim 9, wherein the direction in which the first connecting pin extends is perpendicular to the first conducting layer.