Composite power busbar

Abstract

A composite power bus includes multiple buses and an insulating layer that insulates the multiple buses from each other. The multiple buses include a first positive bus, a first negative bus, a second positive bus, and a second negative bus. The cross-section of the composite power bus has a first direction and a second direction perpendicular to each other. Each bus extends along the first direction, and the first positive bus and the first negative bus are arranged along the second direction. The first positive bus and the second negative bus are aligned with each other along the first direction, and the first negative bus and the second positive bus are aligned with each other along the first direction. The bus of this invention is arranged symmetrically in both the first and second directions, which increases the adjacent area of ​​the current inflow and return paths, thereby reducing parasitic inductance and improving parasitic inductance and thermal management issues under high current conditions.

Description

Technical Field

[0001] This invention relates to a composite power bus for transmitting large currents. Background Technology

[0002] Power buses are widely used in various electrical devices, such as electric vehicles and rack-mounted servers. CN209963431U discloses a DC busbar composed of multiple layers, including an insulating layer and positive and negative conductive layers respectively composited on both sides of the insulating layer. The current directions on the two conductive layers are opposite to each other, thereby reducing parasitic inductance. CN104347966A discloses a multilayer busbar including a first conductive layer, a second conductive layer, and a third conductive layer, with the second conductive layer sandwiched between the first and third conductive layers. The polarity of the second conductive layer is different from that of the first and third conductive layers to increase current and reduce parasitic inductance. However, as the demand for increased current becomes more urgent, the aforementioned power buses still exhibit significant parasitic inductance. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a composite power bus that can reduce parasitic inductance.

[0004] To solve the above problems, the present invention can adopt the following technical solution: a composite power bus, which includes multiple buses and an insulating layer that insulates the multiple buses from each other. The multiple buses include a first positive bus, a first negative bus, a second positive bus, and a second negative bus. The cross-section of the composite power bus has a first direction and a second direction that are perpendicular to each other. Each bus extends along the first direction. The first positive bus and the first negative bus are arranged along the second direction. The first positive bus and the second negative bus are aligned with each other along the first direction. The first negative bus and the second positive bus are aligned with each other along the first direction.

[0005] Compared with the prior art, the busbar of the present invention is arranged symmetrically in both the first and second directions, which increases the adjacent area of ​​the current inflow path and return path, thereby reducing parasitic inductance and improving the parasitic inductance and thermal management problems under high current environment. Attached Figure Description

[0006] Figure 1 This is a perspective view of the composite power bus according to the first embodiment of the present invention.

[0007] Figure 2 yes Figure 1 Cross-sectional view.

[0008] Figure 3 yes Figure 1 Another perspective of the exploded 3D view.

[0009] Figure 4 This is a cross-sectional view of the composite power bus according to the second embodiment of the present invention.

[0010] Figure 5 yes Figure 4 A three-dimensional exploded view.

[0011] Figure 6 This is an exploded perspective view of the composite power bus according to the third embodiment of the present invention.

[0012] Figure 7 yes Figure 6 3D exploded view of the central busbar.

[0013] Figure 8 yes Figure 6 Cross-sectional view along the dashed line AA.

[0014] Figure 9 This is an exploded perspective view of the composite power bus according to the third embodiment of the present invention.

[0015] Figure 10 yes Figure 6 Cross-sectional view along the dashed line BB.

[0016] Figure 11 This is a perspective view of a composite power bus according to the fourth embodiment of the present invention, wherein the insulating layer is not shown.

[0017] Component symbol explanation: Composite power bus 100 Insulating layer 10, outer ring 101, inner partition 102, receiving cavity 103. Busbar 11, First positive busbar 111, first negative busbar 112 Second positive busbar 121, second negative busbar 122 Third positive busbar 131, third negative busbar 132 Fourth positive busbar 141, Fourth negative busbar 142, Composite power bus 200, insulation layer 20, Positive busbar 21, first horizontal plate 211, second horizontal plate 212, vertical plate 213. Negative busbar 22, third horizontal plate 221, fourth horizontal plate 222, vertical plate 223. Insulation layer 30, First positive busbar 311, first negative busbar 312 Second positive busbar 321, second negative busbar 322 Through holes 341, 342, abutting columns 331, 332, 333, 334, Insulation layer 40, First positive busbar 411, first negative busbar 412 Second positive busbar 421, second negative busbar 422 Through holes 441, 442, Conductive cylinders 431 and 432, stepped surface 433. First positive busbar 511, first negative busbar 512 Second positive busbar 521, second negative busbar 522 Positive electrode connector 51, negative electrode connector 52. Detailed Implementation

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below. The described embodiments are some, but not all, of the embodiments of the present invention.

[0019] Figure 1-3 A composite power bus 100 according to a first embodiment of the present invention is shown, which includes a plurality of buses 11 and an insulating layer 10 insulating the plurality of buses from each other. The plurality of buses 11 includes a first positive bus 111, a first negative bus 112, a second positive bus 121, and a second negative bus 122. Figure 2 As shown, the cross-section of the composite power bus 11 has a first direction XX and a second direction YY that are perpendicular to each other. Each bus 11 extends along the first direction XX. The first positive bus 111 and the first negative bus 112 are arranged along the second direction YY. The first positive bus 111 and the second negative bus 122 are arranged and aligned with each other along the first direction XX. The first negative bus 112 and the second positive bus 121 are arranged and aligned with each other along the first direction XX. With the same spacing, this type of bus is arranged symmetrically in both the first and second directions, which increases the adjacent area of ​​the current inflow path and return path, thereby reducing parasitic inductance and improving parasitic inductance and thermal management problems under high current conditions. In this embodiment, the current can be as high as 400A to 2000A. Moreover, this structure is the simplest. It should be noted that the terms "first," "second," "third," "fourth," etc., are used to distinguish similar components and do not represent a sequence.

[0020] In an optimized configuration, the insulating layer 10 is formed from a silicone sleeve. The silicone sleeve has an outer ring 101 and multiple inner partitions 102. Multiple receiving cavities 103 are formed between the outer ring 101 and the multiple inner partitions 102, and the busbars 11 are inserted into the corresponding receiving cavities 103 one by one. Of course, in other embodiments, the outer side of each busbar can be wrapped with silicone, sprayed with insulating varnish, or wrapped with an insulating film to form the insulating layer 10.

[0021] In the optimized configuration, the first positive bus 111 and the first negative bus 112 are aligned with each other in the second direction YY, and the second positive bus 121 and the second negative bus 122 are aligned with each other in the second direction. This further reduces the inductance.

[0022] The multiple buses further include a third positive bus 131, a third negative bus 132, a fourth positive bus 141, and a fourth negative bus 142. The first positive bus 111, the first negative bus 112, the third positive bus 131, and the third negative bus 132 are arranged sequentially along a second direction and aligned with each other. The second negative bus 122, the second positive bus 121, the fourth negative bus 142, and the fourth positive bus 142 are arranged sequentially along a second direction YY and aligned with each other; the third positive bus 131 and the fourth negative bus 142 are arranged aligned with each other along a first direction, and the third negative bus 132 and the fourth positive bus 141 are arranged aligned with each other along a first direction. In this way, while further increasing current transmission, the high current requirement is met.

[0023] Figure 4-5 The first embodiment of the present invention is shown. The composite power bus 200 includes a positive bus 21, a negative bus 22, and an insulating layer 20 that insulates the positive and negative buses from each other. The two buses have a continuous U-shaped nested structure. (See reference...) Figure 4 As shown, viewed in cross-section of the composite power bus 11, the positive bus 21 includes a first horizontal plate 211, a second horizontal plate 212, and a vertical plate 213 connecting the first and second horizontal plates; the negative bus 22 includes a third horizontal plate 221, a fourth horizontal plate 222, and a vertical plate 223 connecting the first and second horizontal plates. The horizontal plates extend in a first direction, and the two U-shaped buses intersect each other. Thus, the first horizontal plate 211, the third horizontal plate 221, the second horizontal plate 212, and the fourth horizontal plate 222 are stacked sequentially along a second direction, forming a positive-negative-positive-negative arrangement. This allows the single-polarity buses to overlap in space, optimizing the terminal wiring position and making it suitable for space-constrained environments.

[0024] Figure 6-8The third embodiment of the present invention is shown. A first positive bus 311, a first negative bus 312, a second positive bus 321, and a second negative bus 322 are arranged in parallel along a second direction, and an insulating layer 30 provides insulation between the busbars. The first negative bus 312 and the second positive bus 321, located in the middle, are provided with multiple through holes 341 and 342. The first positive bus 311 and the second positive bus 312 are respectively provided with abutting posts 331 and 332 that pass through the through hole 341 of the first negative bus 312 and abut against each other. Similarly, the first negative bus 312 and the second negative bus 322 are respectively provided with abutting posts 333 and 334 that pass through the through hole 342 of the second positive bus 321 and abut against each other. Thus, the surface of the busbar is provided with a matrix of three-dimensional abutment pillars and recessed through holes, realizing three-dimensional geometric nesting, maximizing the coupling area, and achieving extremely low inductance.

[0025] Figure 9-10 The fourth embodiment of the present invention is shown, which is similar to the third embodiment. A first positive bus 411, a first negative bus 412, a second positive bus 421, and a second negative bus 422 are arranged in parallel along a second direction, and an insulating layer 40 provides insulation between the aforementioned buses. The first negative bus 412 and the second positive bus 421, located in the middle, are provided with multiple through holes 441 and 442. Multiple conductive cylinders 431 pass through the through holes 441 of the first negative bus 412 to electrically connect the first positive bus 411 and the second positive bus 421 to each other. Multiple conductive cylinders 432 pass through the through holes 442 of the second positive bus 421 to electrically connect the first negative bus 412 and the second negative bus 422 to each other. In this way, the coupling area is maximized, achieving extremely low inductance.

[0026] In the optimized design, the first negative busbar 412 and the second positive busbar 421, located in the middle, are provided with multiple fixing holes (unnumbered). The two ends of the conductive cylinders 431 and 432 are respectively fixed to the corresponding fixing holes, and are secured by interference fits such as riveting or screw locking. In this way, it has both limiting function and vertical conduction, and the structural strength is better. In the optimized design, the two ends of the conductive cylinders are reduced in size, forming stepped surfaces 433. The stepped surfaces 433 abut against the surface of the corresponding busbars, thereby achieving better connection.

[0027] Figure 11 The fifth embodiment of the present invention is shown, which, based on the fourth embodiment, adds side overlap pieces. Multiple positive electrode overlap pieces 51 overlap the sides of the first positive electrode bus 511 and the second positive electrode bus 521, and multiple negative electrode overlap pieces 52 overlap the sides of the first negative electrode bus 512 and the second negative electrode bus 522.

[0028] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A composite power bus comprising a plurality of bus bars and an insulation layer insulating the plurality of bus bars from each other, the plurality of bus bars comprising a first positive bus bar, a first negative bus bar, a second positive bus bar, and a second negative bus bar, the composite power bus characterized by: The cross-section of the composite power bus has a first direction and a second direction that are perpendicular to each other. Each bus extends along the first direction. The first positive bus and the first negative bus are arranged along the second direction. The first positive bus and the second negative bus are arranged and aligned with each other along the first direction. The first negative bus and the second positive bus are arranged and aligned with each other along the first direction.

2. The composite power bus of claim 1, wherein: The insulating layer is formed by a silicone sleeve, which has an outer ring and multiple inner partitions. Multiple receiving cavities are formed between the outer ring and the multiple inner partitions, and the busbars are inserted into the corresponding receiving cavities one by one.

3. The composite power bus of claim 1, wherein: The first positive bus and the first negative bus are aligned with each other in the second direction, and the second positive bus and the second negative bus are aligned with each other in the second direction.

4. The composite power bus of claim 1, wherein: The plurality of busbars further include a third positive busbar, a third negative busbar, a fourth positive busbar, and a fourth negative busbar; The first positive bus, the first negative bus, the third positive bus, and the third negative bus are arranged sequentially and aligned with each other along the second direction; The second negative bus, the second positive bus, the fourth negative bus, and the fourth positive bus are arranged sequentially and aligned with each other along the second direction; The third positive bus and the fourth negative bus are arranged and aligned with each other along the first direction.

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