Double busbar with insulators

Abstract

The invention relates to a double busbar (100) with an insulator (102), wherein the double busbar (100) comprises two busbars (104) which are separated from each other by insulation (106) outside of the ends (108, 110) and are stacked to form a stack, wherein the busbars (104) each have a connection in the ends (108, 110) and the ends (108, 110) are of different lengths, wherein the insulator (102) has a flat parting portion (112) and a shaped An interface portion (126), wherein the parting portion (112) is as wide as the ends (108, 110) and at least as long as the shorter end (108), wherein the parting portion (112) is as thick as the gap between the ends (108, 110) stacked on each other, wherein the parting portion (112) is arranged between the ends (108, 110) and isolates the ends (108, 110) from each other, and wherein the interface portion (126) at least partially isolates at least one of the interfaces.

Description

Technical Field

[0001] The invention relates to a double busbar with an insulator. Background Art

[0002] The invention will be described below primarily in conjunction with an on-board power supply, but can be used in any application for transmitting electrical loads, in particular large electrical loads with high powers, for example greater than 10 kW, or with high voltages, for example greater than 100 V.

[0003] In the vehicle's low-voltage power supply, the conductive metal sheet of the vehicle body can be used as ground, thereby eliminating the need for a separate return line. As a result, almost half of all cables in the vehicle can be eliminated.

[0004] For example, automotive high voltages exceeding 300V, or even exceeding 700V, can be used to transmit large electrical loads. Busbars constructed of solid metal can be used for automotive high voltages. If busbars are used, separate positive and negative busbars may be required for safety reasons. The positive and negative busbars can be designed as dual busbars. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide a double busbar with an improved insulator using a structure as simple as possible. In this case, the improvement may, for example, relate to an improvement in the installability of the insulator and / or an improvement in the electrical insulation of the busbar.

[0006] This object is achieved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the drawings.

[0007] In electric vehicles, high currents are required to transmit driving power, braking power, or recuperation power, even at high vehicle voltages. This current generates electromagnetic fields around the vehicle's current-carrying conductors. Conductors can be shielded to reduce or even prevent field radiation. Alternatively or additionally, feeder and return conductors can be arranged as parallel and close together as possible, as the electromagnetic fields caused by opposing currents cancel each other out.

[0008] Even in the case of busbars, the feeder busbar and return busbar can be arranged very close together by stacking the two busbars congruently. The stacked busbars are then individually electrically isolated. This arrangement is referred to as a double busbar arrangement.

[0009] In order to maintain the cancellation effect also at the contact points, the approach proposed here proposes an isolating profile for a double-busbar power transmission system which also allows isolation of the potential at the contact points.

[0010] A double busbar with an insulator is proposed, wherein the double busbar has two busbars that are isolated from each other at the ends by insulation and are stacked to form a stack, wherein each busbar has an interface at the end and the ends are of different lengths, wherein the insulator has a flat parting portion and a molded interface portion, wherein the parting portion is as wide as the end and at least as long as the shorter end, wherein the parting portion is as thick as the gap between the stacked ends, wherein the parting portion is arranged between the ends and isolates the ends from each other, wherein the interface portion at least partially isolates at least one of the interfaces.

[0011] A busbar can be a solid, long metal sheet. For example, the busbar can be made of aluminum or copper. Aluminum or aluminum alloys have good electrical conductivity, are lightweight, and have low material costs. Copper or copper alloys can have higher electrical conductivity than aluminum or aluminum alloys. Furthermore, copper or copper alloys can be resistant to oxidation and have low contact resistance. The busbar can have a rectangular conductor cross-section. Here, the busbar can be elongated and have a length, for example, greater than 0.5 m, preferably greater than 1 m, and a width, for example, between 0.5 cm and 10 cm, preferably between 1 cm and 5 cm. The busbar can also have a thickness, for example, between 1 mm and 10 mm. The busbar can be insulated on all sides, i.e., surrounded by an insulating layer. For example, the insulation can be made of a plastic material, which can be a thermoplastic. The busbar can be overmolded with a thermoplastic. The insulation can have properties designed for high voltage motor vehicle applications, up to 1000 volts DC. In particular, the thickness of the insulation material ensures insulation strength against high voltage motor vehicle applications.

[0012] A double busbar can consist of two busbars of equal size. These two busbars can be stacked on top of each other on the flat side. The busbars can also be placed very close together. The busbars can be arranged congruently. The double busbar can be covered with a plastic material. Alternatively or additionally, the double busbar can be covered with a textile material. For example, the textile material can be wrapped around the double busbar as a textile tape. The busbar can be stripped at one end, i.e., the insulation and sheathing can be removed at least partially, for example. The double busbar can also be shielded from electromagnetic field radiation by a conductive sleeve.

[0013] When installed, one busbar in the dual busbar system can be connected to the positive potential of the vehicle's high voltage. The other busbar can be connected to the negative potential of the vehicle's high voltage. The currents flowing through the two busbars thus flow in opposite directions and are of equal magnitude. Due to the spatial proximity of the busbars in the dual busbar system, the generated electromagnetic fields essentially cancel each other out.

[0014] The insulator can be made of a plastic material. In particular, the insulator can be made of a thermoplastic. The insulator can be a separate component manufactured independently of the double busbars. For example, the insulator can be a prefabricated injection-molded part. The insulator can be an intermediate piece for placement between the busbars. The geometry and dimensions of the insulator are determined before assembly with the busbars. The insulator can be connected to the busbars in a force-fitting and / or form-fitting manner, but preferably not in a material-fitting manner. The insulator can be reversibly positioned between the busbars. If necessary, the insulator can be removed from the busbars without damage.

[0015] The parting portion may be substantially flat and planar. The parting portion may be adapted to fit the end of the busbar. The interface portion may have a multi-dimensional shape and at least partially follow the contour of at least one of the interfaces.

[0016] Along at least one side edge, the parting portion may have a guide surface oriented in the main extension direction of the generatrix. The guide surface may be oriented perpendicular to the surface of the parting portion. The guide surface may prevent the parting portion from slipping out of the gap between the ends.

[0017] The parting portion may have at least one guide surface for the shorter end and at least one guide surface for the longer end. The insulator may align the busbars with each other and prevent the busbars from sliding relative to each other through the guide surfaces for the two ends.

[0018] The at least one guide surface can have a recess for a connector lug protruding laterally from the longer end of the respective connector and / or a recess for a connector lug protruding laterally from the shorter end. The connector lugs can be laterally connected to the respective end. The connector itself can be arranged on the connector lugs. The recesses can secure the position of the insulator in the main extension direction of the busbar.

[0019] The parting portion may have at least one stop surface oriented transversely to the main extension direction of the busbar. The stop surface may cover an end face of one of the busbars. The stop surface may fix the position of the insulator in the main extension direction.

[0020] The parting portion may have a stop surface for the shorter end and a stop surface for the longer end. The stop surface may isolate the two end surfaces of the busbar.

[0021] The interface portion can be connected to the parting portion and oriented transversely to the main extension direction of the busbar. The contact direction of the interface can be oriented transversely to the main extension direction. The interface portion can be oriented transversely to the parting portion.

[0022] The interface portion can be cylindrical and designed to isolate the socket arranged on the longer end as the interface. The interface portion can be arranged on the extension of the parting portion. The interface portion can be designed as a shell for the socket.

[0023] The interface portion may have an annular portion for isolating one end face of the socket. The annular portion may surround a notch for the socket mating piece and ensure contact safety of the socket.

[0024] The interface portion may be rib-shaped and designed to isolate the interface lugs projecting laterally from the longer end from the interface lugs projecting laterally from the shorter end.The interface portion may be a rib extending between the interface lugs and electrically isolating them from each other.

[0025] The interface portion may be in the shape of a cross rib. The interface portion may have a cross-shaped cross section. The interface lugs may be arranged in parallel offset planes. The interface lugs may be arranged in diagonally opposite quadrants of the cross shape. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Advantageous embodiments of the present invention will be explained below with reference to the accompanying drawings, in which:

[0027] Figure 1 A diagram showing a double busbar with insulators according to one embodiment;

[0028] Figure 2 A diagram showing an insulator according to one embodiment;

[0029] Figure 3 A diagram showing a double busbar with insulators according to one embodiment; and

[0030] Figure 4 A diagram illustrating an insulator according to one embodiment is shown.

[0031] The accompanying drawings are merely schematic illustrations and serve only to explain the present invention. Identical or identical components are always provided with the same reference numerals. DETAILED DESCRIPTION

[0032] For ease of understanding, Figure 1-4 The reference numerals are used as reference in the following description.

[0033] Figure 1 A diagram of a double busbar 100 with an insulator 102 is shown according to one embodiment. Figure 2 A diagram of the insulator 102 is shown.

[0034] The double busbar 100 has two busbars 104, each of which is enclosed by an insulation 106. The ends 108, 110 of the busbars 104 are stripped of insulation and exposed. The busbar 104 with the short end 108 is Figure 1 Located below the busbar 104 having the long end 110. Figure 2 , the insulator is shown upside down.

[0035] The parting section 112 of the insulator 102 is positioned between the ends 108, 110 and separates them from each other. The flat sides of the ends 108, 110 abut against the parting surface 114 of the parting section 112. The parting section 112 has surrounding surfaces on three sides. Guide surfaces 116 are perpendicular to the parting surface 114 and oriented in the main extension direction of the busbar 104. The side surfaces of the ends 108, 110 abut against the guide surfaces 116. The insulator 102 is aligned in a form-fitting manner by the guide surfaces 116 on the ends 108, 110.

[0036] The stop surface 118 is also oriented perpendicular to the parting plane 114 but transversely to the main extension direction of the busbar 104. The end faces of the ends 108 and 110 abut against the stop surface 118. The insulator 102 is aligned on the busbar 104 in the main extension direction by the stop surface 118 in a form-fitting manner. Because the ends 108 and 112 are of different lengths, the parting plane 114 extends beyond the stop surface 118 for the short end 108, while the stop surface 118 for the long end 110 is offset in the main extension direction relative to the stop surface 118 for the short end 108.

[0037] Each end 108, 110 has an interface lug 120. The interface lug 120 protrudes laterally from the end 108, 110. Contact pins 122 are arranged at the ends of the interface lugs 120 as interfaces for the double busbar 100. The contact pins 122 are oriented perpendicular to the interface lugs 120. The guide surface 116 has a recess 124 for the interface lugs.

[0038] The interface portion 126 of the insulator 102 is arranged between the interface lugs 120. The interface portion 126 protrudes laterally from the parting portion 112. The interface portion 122 is rib-shaped, in particular, the interface portion 122 is cross-rib-shaped.

[0039] The ends 108 , 110 and the insulator 102 are surrounded by a housing 128 . Figure 1 Only one half of the housing 128 is shown. The contact pins 122 protrude from the housing 128.

[0040] Figure 3 A diagram of a double busbar 100 with an insulator 102 is shown according to one embodiment. Figure 4 A diagram of an insulator 102 is shown. The double busbar 100 corresponds substantially to Figure 1 In contrast, the busbar 104 has, on its flat sides at its ends 108 , 110 , sockets 300 oriented perpendicularly to the main extension direction, serving as interfaces for the double busbar 100 .

[0041] Here, the parting section 112 has a stop surface 118 only for the long end 110. The interface section 126 is cylindrical and surrounds the socket 300 of the long end 110. The interface section 126 also has an annular portion 302 oriented parallel to the parting surface 114. The annular portion 302 is arranged on one end face of the socket 300 and insulates the end face.

[0042] The socket 300 of the shorter end portion 108 is insulated by its own insulating cap. The interface portion 126 and the insulating cap protrude from a half of the housing 128 (not shown).

[0043] In other words, an isolation profile for a dual-busbar power transmission system is proposed.

[0044] In addition to the classic round conductors and single busbar systems used in electric vehicles, double busbar systems can also be used to transmit power. These offer the advantage of reduced electromagnetic field emission due to field cancellation. This field cancellation results from the geometric arrangement of overlapping rectangular busbars with identical coverage and minimal spacing between them. Interfaces with contact systems are required to connect these double busbar systems to components such as charging sockets, switch boxes, or batteries.

[0045] In the contact area, the busbar strands are stripped of their insulation sheath to provide the accessibility required for connection and surface technology. The operating voltages in the electric vehicle range place high demands on the insulation concept in the busbar gap with regard to dielectric strength in the contact area and to avoid creepage distances.

[0046] The method provides a geometry for an insulating component in a busbar gap, which on the one hand keeps the individual busbar strands at a predetermined EMC-optimal distance via the spacers, reliably isolates the potentials from one another, and ensures touch-proof protection by covering the contact surfaces.

[0047] The basic geometry features an H-shaped profile with transverse fins to increase creepage distances. It is slipped onto the busbar end from the end of the double busbar strand and locked in place with a clip. Furthermore, the insulating geometry can cover one or both contacts of the interface part (plug or plug) to also meet touch-proof requirements.

[0048] Alternatively, the housing around the double busbar system can be filled with a casting compound, thereby filling the spaces between the contact pieces. However, casting is time-consuming during production (filling and curing time). Undetected air pockets (shrinkage cavities) can create creepage distances between the contact pieces. This results in a heavier component, as the casting compound usually completely fills the housing volume.

[0049] As electric vehicle power requirements continue to rise, protecting occupants from electromagnetic stress (ICNIRP) is becoming increasingly important. High-voltage (HV) double busbar systems can transmit large amounts of energy while maintaining low electromagnetic field emissions. These busbar systems require suitable outdoor-compatible interfaces.

[0050] Compared to previous potting solutions, the isolation of the contact parts using pluggable insulation geometries can be achieved more cost-effectively, more lightweight, more reliably, faster to manufacture, and easier. The insulation can be produced in advance and allows the housing parts to be disassembled and reassembled in the event of damage or recycling.

[0051] These drawings show the insulation in the fitted position. The gaps between the rails are filled with the insulation outline in the contact area. Figure 1 An example of a contact-through with a so-called lug screw connection is shown. In the case of lug contacts, the insulating member is ensured by spacing fins at a distance suitable for observing the creepage distance. Figure 2 An isometric view of the insulation concept using a lug contact as an example. The functional features of the side guides for the aluminum busbar and the spacer fins on the insulating core rods, which ensure the creepage distance between the spiral lugs, can be seen.

[0052] In addition, Figure 3 In the case of the socket contacts, the insulation provided by the top cover also provides touch protection. The components are each inserted into the lower housing half; the upper housing half is not shown. Figure 4 An isometric view of the insulation concept using a socket contact as an example. The functional features of the side guides for the aluminum busbars can also be seen here. Here, creepage distances are maintained by covering one socket with an insulating dome, which also covers the contact to ensure touch protection.

[0053] Since the above detailed description of the device and method is an embodiment, those skilled in the art can modify them in a wide range in a common way without departing from the scope of the present invention. In particular, the mutual mechanical arrangement and dimensional relationship of the various components are only exemplary.

[0054] Reference Signs List

[0055] 100 double busbar

[0056] 102 Insulator

[0057] 104 busbar

[0058] 106 Insulation

[0059] 108 short end

[0060] 110 long end

[0061] 112 Parting Section

[0062] 114 parting surface

[0063] 116 guide surface

[0064] 118 stop surface

[0065] 120 interface lugs

[0066] 122 stylus

[0067] 124 recess

[0068] 126 Interface Area

[0069] 128 housing

[0070] 300 socket

[0071] 302 ring part

Claims

1. A double busbar with insertable insulators, in, The double busbar has two busbars separated from each other by insulation outside the end and stacked into a stack, The busbars each have a connection at the ends and the ends are of different lengths. The insertable insulator has a flat parting portion and a formed interface portion. wherein the parting portion is as wide as the end portion and at least as long as the shorter end portion, wherein the parting portion is as thick as the gap between the ends stacked on each other, The parting portion is inserted between the ends and isolates the ends from each other. Wherein, the interface portion at least partially isolates at least one of the interfaces.

2. The double busbar according to claim 1, wherein: The parting portion has, along at least one side edge, a guide surface oriented in the main extension direction of the generatrix.

3. The double busbar according to claim 2, wherein: The parting portion has at least one guide surface for the shorter end portion and at least one guide surface for the longer end portion.

4. The double busbar according to claim 3, wherein: At least one guide surface has a recess for an interface lug protruding laterally from the longer end and / or a recess for an interface lug protruding laterally from the shorter end.

5. The double busbar according to claim 1, wherein: The parting portion has at least one stop surface oriented transversely to the main extension direction of the generatrix.

6. The double busbar according to claim 5, wherein: The parting portion has a stop surface for the shorter end and a stop surface for the longer end.

7. The double busbar according to claim 1, wherein: The interface portion is connected to the parting portion and is oriented transversely to a main extension direction of the busbar.

8. The double busbar according to any one of claims 1 to 7, wherein: The interface portion is cylindrical and is designed to isolate a socket arranged on a longer end portion that is longer than the interface.

9. The double busbar according to claim 8, wherein: The interface portion has an annular portion for isolating one end surface of the socket.

10. The double busbar according to any one of claims 1 to 7, wherein: The interface portion is rib-shaped and is designed to separate the interface lugs protruding laterally from the longer end from the interface lugs protruding laterally from the shorter end.

11. The double busbar according to claim 10, wherein: The interface portion is in a cross rib shape.

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