Large-current track-type bus duct

Abstract

Apparatus and systems for busbar conduits, busbars, and bus trunking for high-current applications are described. Example components may include a first conductor assembly. The assembly also includes two or more busbar trunks. Each of the two or more busbar trunks is a distribution busbar or a transmission busbar. A first end of each of the two or more busbar trunks is electrically connected to the first conductor assembly. The assembly further includes a second conductor assembly. Each of the two or more busbar trunks is electrically connected to the second conductor assembly at a second end of each of the two or more busbar trunks.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Application No. 63 / 592,459, filed October 23, 2023, entitled “HIGH-AMPERAGE TRACK BUSWAY,” the contents of which are incorporated herein by reference in their entirety. Technical Field

[0002] This article generally deals with power distribution, and more specifically with rail-mounted or continuous access busbars for high-current applications. Background Technology

[0003] Power distribution, or busbar systems, are used to distribute power throughout a building, particularly commercial or industrial buildings. Typically, a busbar system comprises multiple busbar segments connected to each other via busbar joints. Each busbar segment includes a housing that encloses multiple busbars, which, depending on the specific application, may be phase busbars, neutral busbars, or grounding busbars. Summary of the Invention

[0004] In some aspects, the technology described herein relates to a high-current busbar assembly comprising: a first conductor assembly; two or more busbars, each of which is a distribution busbar or a transmission busbar, wherein each of the two or more busbars is electrically connected at a first end to the first conductor assembly; and a second conductor assembly, wherein each of the two or more busbars is electrically connected at a second end to the second conductor assembly.

[0005] In some respects, the technology described herein relates to a component in which two or more busbars are connected in parallel with each other.

[0006] In some respects, the technology described herein relates to a component in which each of a first conductor assembly and a second conductor assembly is sized to accommodate two busbar trunks.

[0007] In some respects, the technology described herein relates to a component in which each of a first conductor assembly and a second conductor assembly is sized to accommodate two busbar trunks.

[0008] In some respects, the technology described herein relates to a component in which at least one of two or more busbar trunks is a distribution busbar.

[0009] In some respects, the technology described herein relates to a component in which the distribution bus is an open-type trough distribution trunk line.

[0010] In some respects, the technology described herein relates to a component, further comprising one or more power supply units attached to a distribution bus between a first conductor assembly and a second conductor assembly.

[0011] In some respects, the technology described herein relates to a component, which further includes one or more connector adapter pieces for connecting a first conductor assembly to two or more busbar trunks.

[0012] In some respects, the technology described herein relates to an assembly in which at least one of a first conductor assembly and a second conductor assembly is attached to another busbar assembly.

[0013] In some respects, the technology described herein relates to a component wherein the rated current of the component is at least 1600A.

[0014] In some aspects, the technology described herein relates to a method of manufacturing a high-current busbar assembly, the method comprising: providing a first conductor assembly; electrically connecting two or more busbar trunks to the first conductor assembly, wherein each of the two or more busbar trunks is a distribution busbar or a transmission busbar, wherein each of the two or more busbar trunks is electrically connected to the first conductor assembly at a first end; and electrically connecting a second conductor assembly to the two or more busbar trunks, wherein each of the two or more busbar trunks is electrically connected to the second conductor assembly at a second end.

[0015] In some respects, the technology described herein relates to a method in which two or more busbars are connected in parallel with each other.

[0016] In some respects, the technology described herein relates to a method in which each of a first conductor assembly and a second conductor assembly is sized to accommodate two busbar trunks.

[0017] In some respects, the technology described herein relates to a method in which each of a first conductor assembly and a second conductor assembly is sized to accommodate two busbar trunks.

[0018] In some respects, the technology described herein relates to a method in which at least one of two or more busbar trunks is a distribution busbar.

[0019] In some respects, the technology described herein relates to a method in which the distribution bus is an open-type trough distribution trunk line.

[0020] In some respects, the technology described herein relates to a method that further includes attaching one or more power supply units to a distribution bus between a first conductor assembly and a second conductor assembly.

[0021] In some respects, the technology described herein relates to a method that further includes connecting one or more connector adapter pieces to a first conductor assembly for connection to two or more busbar trunks.

[0022] In some respects, the technology described herein relates to a method in which at least one of a first conductor assembly and a second conductor assembly is attached to another busbar assembly.

[0023] In some respects, the technology described herein relates to a method in which the component has a rated current of at least 1600A. Attached Figure Description

[0024] This disclosure is illustrated and described with reference to various accompanying drawings, in which similar reference numerals denote similar method steps and / or system components, wherein: Figure 1 A cross-section of an example power distribution track according to various embodiments of the present disclosure is shown; Figure 2 Example plug-in units according to various embodiments of the present disclosure are shown; Figure 3 A plug-in unit for engaging with a power distribution rail is shown according to various embodiments of the present disclosure; Figure 4A and Figure 4B A cross-section of a high-current track-type busbar trunking according to various embodiments of the present disclosure is shown; Figure 5 A structural prototype of a high-current track-type busbar trunking according to various embodiments of the present disclosure is shown; Figure 6 Examples of high-current trunk busbars and connector assemblies with continuous access busbar trunking functionality are shown according to various embodiments of the present disclosure; Figure 7 Example busbars for high-current track-type busbar trunking are shown according to various embodiments of the present disclosure; Figure 8 A model of an example trunk busbar according to various embodiments of the present disclosure is shown; Figure 9 A double busbar trunking system with two distribution buses is shown according to various embodiments of the present disclosure; Figure 10 This illustration shows a double busbar trunking system having a first distribution busbar and a first transmission busbar according to various embodiments of the present disclosure; Figure 11 A three-bar busbar trunking system with a first distribution bus, a second distribution bus, and a first transmission bus is shown according to various embodiments of the present disclosure; Figure 12A three-busbar trunking system having a first distribution bus, a second distribution bus, and a transmission bus is shown according to various embodiments of the present disclosure; Figure 13 A three-busbar trunking system having a first distribution bus, a first transmission bus, and a second transmission bus is shown according to various embodiments of the present disclosure; Figure 14 A three-busbar trunking system having a first transmission bus, a first distribution bus, and a second transmission bus is shown according to various embodiments of the present disclosure. Figure 15A and Figure 15B Examples of dual busbar conductor assemblies according to various embodiments of this disclosure are shown. Figure 15A ) and three busbar conductor assemblies ( Figure 15B Different conductor components; Figure 16A and Figure 16B This illustration shows a dual busbar power supply assembly according to various embodiments of the present disclosure. Figure 16A ) and three-busbar feeder components ( Figure 16B ); Figure 17A and Figure 17B The installation in the first distribution busbar according to various embodiments of the present disclosure is shown. Figure 17A ) and separate installation ( Figure 17B Connector adapter pieces; Figure 18 This illustration shows a three-busbar trunking system with power tapping units arranged along the distribution busbar, according to various embodiments of the present disclosure; and Figure 19 This is a side view of a double busbar trunking having a first distribution busbar 905A and a first transmission busbar 1005A according to various embodiments of the present disclosure. Detailed Implementation

[0025] This disclosure can be more readily understood by referring to the following detailed description, which is incorporated herein by reference and forms part of the accompanying drawings. It should be understood that this disclosure is not limited to the specific devices, methods, conditions, or parameters described and / or shown herein, and the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to limit the scope of the claimed disclosure. Any and all patents and other publications identified in this specification are incorporated herein by reference as if fully set forth herein.

[0026] Additionally, as used herein (including the appended claims), the singular forms “a,” “an,” and “the” include the plural, and references to a particular numerical value include at least that particular value, unless the context clearly specifies otherwise. A range herein may be expressed as from “about” or “approximately” one particular value and / or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from that one particular value and / or to that other particular value. Similarly, when a value is expressed as an approximation, the use of the antecedent “about” should be understood to indicate that the particular value constitutes another embodiment.

[0027] Power distribution systems for lighting and other electrical needs typically include installed busbar trunking to which lighting fixtures, power outlets, and other electrical components can be attached. In a typical system, the busbar trunking comprises an elongated housing with a downward-facing opening and containing the necessary conductors and insulation. Various output devices can be physically attached to the housing at any point along its length, and these output devices have portions extending upwards into the housing and connecting to the conductors housed therein. Such busbar trunking systems are desirable because they are relatively easy to install and modify, and offer a high degree of flexibility in the placement and repositioning of output devices such as lighting fixtures and power output devices.

[0028] The disclosed embodiments of the technology are designed for flexible, scalable and reliable power distribution for high-current applications, including data centers, mission-critical facilities, retail locations, manufacturing plants and the like.

[0029] Initially, high-current power distribution systems were typically cable bus systems installed in overhead cable trays or under raised floors, with the underfloor area housing leads and cables that provide high-current power to multiple devices, such as server racks. For example, an embodiment described in U.S. Patent No. 10,141,731 includes an underground portion where the cable bus is housed in a sheath specifically biased for ventilation or electrical cooling to meet the high-current requirements of the cables. However, this conventional underfloor approach has several drawbacks, including: the high cost of raised floors; the need for maintenance to remove unused cables, which are often discarded; the risk of human error when using circuit breakers and cables not explicitly associated with a given load; the total weight of conventional cables used in these applications; and unclear and / or low short-circuit withstand values.

[0030] Furthermore, traditional bus conduit systems have been used to provide high-current power distribution in a variety of applications, including industrial facilities, commercial and office buildings, power plants, and gray-space data center installations. These products typically range from 600-6300A, but are primarily designed to electrically connect various devices together or distribute power in low-density environments. Bus conduit systems have fixed locations for tapping, which limits the number of connections available within a given bus conduit section. However, as the tap density requirements for meeting specific equipment loads continue to increase, traditional bus conduits cannot provide the sufficient number of taps needed to provide adequate connections within a given bus conduit length.

[0031] Existing busbar systems support currents ranging from 20-30A (see, for example, U.S. Patent No. 7,744,386) to 100-1200A (see, for example, U.S. Patent No. 9,438,014). However, these currents are insufficient to support the growing demands of data centers, mission-critical facilities, and manufacturing plants. Embodiments of the disclosed technology are rated to support 1600-6300A and provide the flexibility, scalability, and reliability of busbar systems, thereby mitigating the drawbacks and limitations of the aforementioned approaches.

[0032] Figure 1 A cross-section of a power distribution track 10 is shown. The busbar trunking may include multiple track segments 10 connected end-to-end to form a distribution system. Each track segment 10 is typically up to 20 feet long, and any number of segments can be connected to form a long-distance busbar trunking for power distribution. Plug-in units (e.g., such as...) Figure 2 (As shown) It can be installed at any point along the busbar, except at the connection between adjacent sections of the track.

[0033] In some embodiments, each segment of the track 10 includes a housing 12, which is a grooved extruded aluminum product. The housing 12 can be attached to a ceiling, wall, etc., and typically has the opening of the groove or access slot 13 facing downwards, such as... Figure 1 As shown. Rail 10 further includes an insulating support 14 fixed in housing 12 and a plurality (typically 3 or 4) of conductive busbars 16 within the insulating support. In the example, the busbars 16 in rail 10 have a unique configuration that provides robust contact pressure and a large contact surface area, and can mate with tabs on taps that can be inserted into rail 10 at virtually any point along its length.

[0034] In some embodiments, busbar 16 is made of copper strip material, which may be tempered to approximately semi-hard to give it elastic or spring-like properties. The thickness of the copper strip can be from about 0.010 to 0.125 inches. In one example, the thickness of the copper strip is about 0.030 to 0.050 inches. In another example, the thickness of the copper strip is about 0.040 inches. In other embodiments, aluminum strip may be used instead of copper.

[0035] Figure 2 An example plug-in unit 50, sometimes also called a junction box, is shown. As illustrated, the plug-in unit 50 may include a housing 52, an overcurrent protection device 54, an electrical socket 58, a plug plate 56, and multi-pole conductive tabs 42 on the plug plate for electrical contact with the busbars 16 in the rail 10. The plug-in unit 50 can be inserted into the rail 10, such as... Figure 3 As shown, the insert plate 56 can be inserted at almost any point along its length by inserting it into the opening of the housing 12 and rotating the device, for example, clockwise by 90 degrees. Hanging bolts ( Figure 2 (Not shown) can be used to secure the device 50 in the track 10. In some embodiments, the rated current of the insert 56 is 160A, and the rated current of the multi-pole conductive insert is 250A.

[0036] Figures 1 to 3 The embodiments shown are described in further detail in U.S. Patent No. 6,039,584, which is incorporated herein by reference in its entirety.

[0037] Figure 4A and Figure 4B A cross-sectional view of an example high-current busbar trunking 400 according to the disclosed technology is shown. Figure 4A The high-current busbar 400 shown includes a trunk busbar 410 horizontally adjacent to a continuous access busbar 420. The trunk busbar 410 includes a plurality of busbars (e.g., a first internal assembly 414), each busbar configured to engage one end of a compressed flat trunk conductor 416 (or plate). The other end of the compressed flat trunk conductor 416 is connected to, but electrically isolated from, the outer housing of the high-current busbar 400 (e.g., an external assembly 405). The continuous access busbar 420 also includes a plurality of busbars (e.g., a second internal assembly 424), each busbar configured to engage a plug-in unit 428 (e.g., ...). Figure 2 The plug-in member 426 of the plug-in unit 50 shown. In some embodiments, continuous access to the busbar 420 may include... Figure 1 One or more segments of the power distribution track shown.

[0038] Figure 4BA high-current busbar trunking 400 is shown, comprising an external assembly 405 including a first cavity 412 (corresponding to a main busbar 410) and a second cavity 422 (corresponding to a continuous access busbar trunking 420) horizontally adjacent to the first cavity 412. The first cavity 412 includes a first internal assembly 414 comprising a plurality of busbars, each configured to engage one end of a compressed flat main conductor 416 (or plate). The second cavity 422 includes a second internal assembly 424, which also includes a plurality of roll-formed or spring-contact busbars, and in the second cavity 422, each of the plurality of roll-formed busbars is configured to engage a tab member 426 of a plug-in unit 428, such as... Figure 4B As shown.

[0039] exist Figure 4A and Figure 4B In the illustrated embodiment, the main busbar reliably carries a large current, the first internal component 414 and the second internal component 424 are electrically coupled to relay current from the main busbar 410 to the continuous access busbar 420, and the plug-in unit 428 is configured to feed current to the devices connected thereto. In this example, the first internal component 414 and the second internal component 424 are electrically coupled by being physically connected to each other. In another example, the first internal component 414 and the second internal component 424 are electrically coupled by connecting the main busbar to the conductive busbar of the continuous access busbar.

[0040] Figure 5 The structural prototype of the high-current busbar trunking 500 is shown, and its cross-section is as follows. Figure 4A and Figure 4B As shown in the figure, the structural equivalent of the high-current busbar 500 includes a structural equivalent of the trunk busbar 510 (similar to the busbar conduit product described earlier) and a structural equivalent of the continuously connected busbar 520. The trunk busbar 510 includes a metal strip representing a compressed flat conductor (or plate) 516. Figure 6 An example of a functional trunk bus 610 is shown, which includes a plurality of conductive strips (or plates) 616-1, 616-2, 616-3, and 616-4. In some embodiments, the conductive strips are formed of copper or aluminum and may be coated with tin or epoxy resin.

[0041] Figure 7 An example busbar for a high-current busbar trunking is shown. As shown, the busbar 16 is typically U-shaped, with a slot 17 and a pair of generally parallel, resilient (spring-like) inner flanges 34 for establishing pressure contact with the tabs on the plug-in unit. The cross-section of the busbar 16 may include a base 36 and two legs 38 extending from the base, as well as inner re-entry flanges 34 extending rearward toward the base 36.

[0042] Refer again Figure 1The dimensions of the slot 20 in the support member 14 and the busbar 16 allow the busbar to be tightly installed in the slot; the size of the slot 17 in the busbar 6 is smaller than the thickness of the insert on the plug-in unit to be inserted into the rail. The inner end flanges 34 on the busbar 16, and in particular the inner contact surfaces 40 on the end flanges, are substantially parallel to each other and... Figure 2 The inserts 42 shown are generally parallel in orientation. The legs 38 of the busbar 16 preferably converge slightly from the base 36 of the busbar to the ends of the legs at the end flange connections. Therefore, the busbar 16 can have a generally trapezoidal shape. The end flange 34 can be freely bent such that its profile conforms to the insert 42 and maintains the parallelism between the two contact surfaces 40 on the flange 34 and the contact surfaces 44 on the insert. This freedom of movement is achieved by the elastic or spring-like properties of the metal of the busbar 16 and the profile of the busbar. The legs 38 can be bent relative to the base 36, and the end flange 34 can be bent relative to the legs.

[0043] As the plug-in unit's insert component is inserted into the busbar, the trapezoidal shape of the busbar gradually transforms into a rectangle as the upper corner of the slot moves outward. Due to the flexibility of the material and the fact that the natural slot size in the busbar is smaller than the insert thickness, the contact surfaces on the busbar remain parallel and firmly pressed against the insert. This design accommodates some variations between slot size and insert thickness while still establishing good surface contact. The total contact surface area between the insert and the busbar is approximately twice the product of the height of the busbar's contact surface portion and the width of the insert. In other words, both sides of the insert are in full contact with the parallel contact surfaces of the busbar. Current flows from the busbar to the plug-in unit through this surface area. When the plug-in unit is removed from the busbar slot, the busbar returns to its natural shape. Compared to existing power distribution systems, this architecture provides a robust contact pressure surface and increases the contact between the busbar and the plug-in unit's inserts.

[0044] Figure 8 A model of an example trunk busbar is shown. As shown in the cross-sectional view on the left, trunk busbar 810 is adjacent to and electrically coupled to busbar 814, which can be configured to be connected to a continuous busbar trunking (e.g., as shown in the left-hand section). Figure 4A , Figure 4B and Figure 5 The aforementioned docking.

[0045] Figures 9 to 19 Various different busbar configurations according to various embodiments of this disclosure are shown. References Figures 9 to 19 The busbar trunking discussed can be referenced. Figures 1 to 8 The various characteristics discussed. For example... Figures 9 to 19As shown, transmission buses and distribution buses can be interchanged depending on the intended use of a given busbar trunking. Therefore, buses (e.g., transmission buses and / or distribution buses) can be positioned to connect conductor assemblies (e.g., double busbar conductor assembly 1500, triple busbar conductor assembly 1550, etc.), as illustrated. The buses discussed herein (e.g., transmission buses and / or distribution buses) can be “busbar trunking.” For example, a distribution busbar can be an open-trough type distribution busbar trunking, and / or a transmission busbar can be a mezzanine busbar trunking type. In various embodiments, buses are connected in parallel with other buses (e.g., Figures 9 to 19 Each transmission bus and / or distribution bus in the diagram can be connected in parallel with each other.

[0046] The various embodiments shown herein may include distribution buses and / or transmission buses. Distribution buses (e.g., first distribution bus 905A, second distribution bus 905B, etc.) may be open to accommodate power supply units (e.g., Figure 18 The power tapping unit is shown. Transmission buses (e.g., first transmission bus 1005A, second transmission bus 1005B, etc.) are enclosed, so no power supply unit can be installed between the two ends of the busbar. For example, a transmission bus may connect to a conductor assembly at each end, but the rest of its length is enclosed, while a distribution bus may connect to a conductor assembly at each end, but is also open to accommodate a power supply unit. Various embodiments described herein illustrate different configurations of distribution buses and / or transmission buses.

[0047] Figure 9 A double busbar trunking 900 with a first distribution busbar 905A and a second distribution busbar 905B is shown according to various embodiments. Double busbar trunking (e.g., Figure 9 900 double busbar trunking Figure 10 A double busbar busbar 1000 (or similar) may include two busbars connecting electrical components (e.g., conductor components). For example, a first distribution busbar 905A and a second distribution busbar 905B connect a first double busbar conductor component 1500A and a second double busbar conductor component 1500B. Figure 10 A double-busbar busbar trunking 1000 with a first distribution busbar 905A and a first transmission busbar 1005A is shown according to various embodiments. As described above, the transmission busbar and the distribution busbar can be interchanged depending on the purpose of the busbar trunking.

[0048] Figure 11 A three-busbar busbar trunking 1100 with a first distribution bus 905A, a second distribution bus 905B, and a first transmission bus 1005A is shown according to various embodiments. Figure 11 middle, Figure 11The first transmission bus 1005A is located between the first distribution bus 905A and the second distribution bus 905B. For example... Figure 12 As shown, the positions of different styles of busbars can be changed according to the use case of the busbar trunking (e.g., Figure 12 The first distribution bus 905A and the second distribution bus 905B are adjacent to each other, but... Figure 11 (Separated by the first transmission bus 1005A). The configuration can be based on the type of power supply unit used (e.g., plug-in unit, power tap unit, etc.). For example, some power supply units may have a large footprint, requiring the distribution bus to be separated. Figures 11 to 14 Various different bus configurations are shown. For example, Figure 12 The diagram shows a three-busbar busbar 1200 having a first distribution busbar 905A, a second distribution busbar 905B, and a first transmission busbar 1005A, wherein... Figure 12 The second power distribution bus 905B is located between the first power distribution bus 905A and the first transmission bus 1005A; Figure 13 This diagram shows a three-busbar busbar 1300 having a first distribution busbar 905A, a first transmission busbar 1005A, and a second transmission busbar 1005B, wherein... Figure 13 The first transmission bus 1005A is located between the first distribution bus 905A and the second transmission bus 1005B; Figure 14 A three-busbar busbar trunking 1400 is shown, comprising a first transmission busbar 1005A, a first distribution busbar 905A, and a second transmission busbar 1005B. Figure 14 The first distribution bus 905A is located between the first transmission bus 1005A and the second transmission bus 1005B.

[0049] Figure 15A and Figure 15B Different conductor assemblies according to various embodiments are shown, such as a double busbar conductor assembly ( Figure 15A ) and three busbar conductor assemblies ( Figure 15B ). Figure 15A and Figure 15B The conductor assembly is monolithic. The conductor assembly can be used to connect various electrical components discussed herein. For example, the conductor assembly can be used to connect busbars to each other (e.g., busbar 1505 can be connected to one or more buses (e.g., the distribution busbar and / or transmission busbar of a first busbar), and busbar 1510 can be connected to one or more other buses (e.g., the distribution busbar and / or transmission busbar of a second busbar). Busbars 1505 and 1510 can be connected to various different electrical components discussed herein (e.g., any number of different busbar connections discussed herein).

[0050] While dual-busbar and triple-busbar conductor assemblies are shown in various embodiments, any number of conductor assemblies of different sizes may be used herein. In various embodiments, the conductor assembly may have one or more accessory recesses 1515, 1520 to allow coupling to a retaining structure (e.g., for installation in a building).

[0051] Figure 16A and Figure 16B A dual busbar feeder assembly is shown according to various embodiments ( Figure 16A ) and three-busbar feeder components ( Figure 16B Power supply assemblies (e.g., dual busbar power supply assembly 1600 and / or triple busbar power supply assembly 1650) can be used to connect multiple busbars to each other. For example, a power supply adapter 1605 of dual busbar power supply assembly 1600 can be connected to another power supply adapter of another dual busbar power supply assembly, and a power supply adapter 1655 of triple busbar power supply assembly 1650 can be connected to another power supply adapter of another triple busbar power supply assembly. Different numbers of buses can be connected using power supply adapters. For example, both single busbar power supply assemblies and dual busbar power supply assemblies can be connected to triple busbar power supply assembly 1650. Power supply adapters 1605 and 1655 can be used to connect to various different electrical components discussed herein.

[0052] Figure 16A and Figure 16B The power supply components all use only the transmission bus (e.g., Figure 16A The first transmission bus 1005A and the second transmission bus 1005B, and Figure 16B The first transmission bus 1005A, the second transmission bus 1005B, and the third transmission bus 1005C are described in the diagram, but in various embodiments, a distribution bus may also be used.

[0053] Figure 17A and Figure 17B The insertion into the distribution busbar according to various embodiments is shown. Figure 17A ) and alone ( Figure 17B Connector adapter pieces. Connector adapter pieces 1700A-1700E can be used to connect different electrical components. For example, connector adapter pieces can be used to connect busbars (e.g., transmission busbars and / or distribution busbars) to conductor assemblies (e.g., double busbar conductor assembly 1500, triple busbar conductor assembly 1550, etc.). Figure 17A As shown, connector adapter pieces 1700A-1700B can be connected to the busbar of the distribution bus (e.g., Figure 19 The busbar port 1900 of the first distribution busbar 905A shown.

[0054] The structure of connector adapter pieces 1700A-1700E can be compatible with... Figure 17BThe connector adapter piece 1700 shown is similar. The connector adapter piece 1700 may be at least partially made of a conductive material (e.g., aluminum, copper, gold, silver, etc.). In various embodiments, the connector adapter piece 1700 may have an L-shape. The connector adapter piece 1700 may include an insertion portion 1750 and a connector portion 1755. The insertion portion 1750 of the connector adapter piece 1700 may be the portion of the connector adapter piece 1700 that inserts into a busbar (e.g., ...). Figure 17A (As shown). Connector portion 1755 can be connected to other electrical components (e.g., other busbars) to carry current. In various embodiments, the connector adapter piece can be U-shaped with two insertion portions. Figure 17A As shown, multiple connector adapter pieces 1700A-1700E can be used to conduct and / or otherwise transmit power.

[0055] Figure 18 A three-busbar busbar trunking with power tap units arranged along a distribution busbar is shown according to various embodiments. Although the power tap units are shown for use with the three-busbar busbar trunking, any number of power tap units (or other power supply units) can be used if one or more distribution buses are provided. As shown, the three-busbar busbar trunking 1800 includes a first distribution busbar 905A, a second distribution busbar 905B, and a transmission busbar 1005A, wherein the first power tap unit 1805A is connected to the first distribution busbar 905A, and the second power tap unit 1805B is connected to the second distribution busbar 905B. Figure 18 The connection method of the power supply tapping unit is the same, and any number of power consumption units can be connected to the power distribution bus.

[0056] Figure 19 This is a side view of a double busbar trunking having a first distribution busbar 905A and a first transmission busbar 1005A according to various embodiments. Figure 19 The electrical busbar shown is an example of any busbar discussed in this disclosure. As described herein, the first distribution busbar 905A may include one or more busbar ports 1900 for accommodating electrical connectors, such as... Figure 17A and Figure 17B The connector adapter piece 1700 is shown. The first transmission bus 1005A may also include one or more busbar ports 1910 for accommodating electrical connectors. Although Figure 19 The first distribution bus and the first transmission bus are shown with busbar ports, but any electrical bus discussed herein can have integral connector probes (e.g., connector adapter pieces can be integrated with a given electrical bus). Figure 19 In the illustrated embodiment, the first distribution busbar 905A includes a press-fit connector extension tab retainer. In various embodiments, a busbar support 1950 may be provided to support the components therein.

[0057] In various embodiments, a high-current busbar assembly is provided, comprising an open-type distribution busbar trunking connected in parallel with one or more other busbar trunkings. The other busbar trunkings are either open-type distribution busbars or sandwich busbar trunkings. The high-current busbar trunking assembly may include multiple ferrule members with a rated current of 100A or higher.

[0058] In various embodiments, busbar connectors can be used to connect open-type busbars to enclosed-type busbars. Busbar connectors can connect any combination of compatible busbar trunking segments. Busbar tap units are compatible with T5 busbar trunking systems.

[0059] Flange plates are added to existing components for component alignment, electrical safety, and intrusion protection. Conductive adapter tabs inserted into the conductors of an open-slot BTS extend from both ends of the BTS and mate with the BTS connector (integral type).

[0060] While this patent document contains numerous specific details, these should not be construed as limiting the scope of any invention or the scope of the claims, but rather as descriptions of features specific to particular embodiments of the particular invention. Features described in the context of individual embodiments in this patent document may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although features may be described as functioning in certain combinations and even initially claimed in this way, in some cases one or more features may be removed from the claimed combination, and the claimed combination may be for sub-combinations or variations thereof.

[0061] Similarly, although the operations are depicted in a specific order in the accompanying drawings, this should not be construed as requiring such operations to be performed in the specific order shown or sequentially, or requiring the execution of all illustrated operations to obtain the desired result. Furthermore, the separation of various system components in the embodiments described in this patent document should not be construed as requiring such separation in all embodiments.

[0062] Only a few implementation methods and examples are described and illustrated, and other implementation methods, enhancements and variations can be implemented based on the content described and illustrated in this patent document.

[0063] Clauses requiring protection Clause 1. A high-current busbar assembly comprising: a first conductor assembly; two or more busbars, each of which is a distribution busbar or a transmission busbar, wherein each of the two or more busbars is electrically connected at a first end to the first conductor assembly; and a second conductor assembly, wherein each of the two or more busbars is electrically connected at a second end to the second conductor assembly.

[0064] Clause 2. Components as described in Clause 1, wherein two or more busbars are connected in parallel to each other.

[0065] Clause 3. The assembly as described in Clause 1, wherein each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

[0066] Clause 4. The assembly as described in Clause 1, wherein each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

[0067] Clause 5. Components as described in Clause 1, wherein at least one of two or more busbar trunks is a distribution busbar.

[0068] Clause 6. Components as described in Clause 5, wherein the distribution bus is an open-type trough distribution trunk line.

[0069] Clause 7. The component as described in Clause 5 further includes one or more power supply units attached to the distribution bus between the first conductor assembly and the second conductor assembly.

[0070] Clause 8. The component as described in Clause 1 further includes one or more connector adapter pieces for connecting the first conductor assembly to two or more busbar trunks.

[0071] Clause 9. The component as described in Clause 1, wherein at least one of the first conductor assembly and the second conductor assembly is attached to another busbar assembly.

[0072] Clause 10. The component as described in Clause 1, wherein the rated current of the component is at least 1600A.

[0073] Clause 11. A method of manufacturing a high-current busbar assembly, the method comprising: providing a first conductor assembly; electrically connecting two or more busbar trunks to the first conductor assembly, wherein each of the two or more busbar trunks is a distribution busbar or a transmission busbar, wherein each of the two or more busbar trunks is electrically connected to the first conductor assembly at a first end; and electrically connecting a second conductor assembly to the two or more busbar trunks, wherein each of the two or more busbar trunks is electrically connected to the second conductor assembly at a second end.

[0074] Clause 12. The method as described in Clause 11, wherein two or more busbars are connected in parallel to each other.

[0075] Clause 13. The method as described in Clause 11, wherein each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

[0076] Clause 14. The method as described in Clause 11, wherein each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

[0077] Clause 15. The method as described in Clause 11, wherein at least one of the two or more busbar trunks is a distribution busbar.

[0078] Clause 16. As described in Clause 15, wherein the distribution bus is an open-type trough distribution trunk line.

[0079] Clause 17. The method described in Clause 15 further includes attaching one or more power supply units to the distribution bus between the first conductor assembly and the second conductor assembly.

[0080] Clause 18. The method as described in Clause 11 further includes connecting one or more connector adapter pieces to the first conductor assembly to connect to two or more busbar trunks.

[0081] Clause 19. The method as described in Clause 11, wherein at least one of the first conductor assembly and the second conductor assembly is attached to another busbar assembly.

[0082] Clause 20. The method as described in Clause 11, wherein the rated current of the component is at least 1600A.

[0083] Clause 21. A high-current busbar assembly, comprising: an external assembly having a first cavity and a second cavity horizontally adjacent to the first cavity, wherein the external assembly is disposed along a longitudinal axis, wherein the first cavity includes a first internal assembly parallel to the longitudinal axis, the first internal assembly being configured to engage a plurality of plates, wherein the second cavity includes a second internal assembly parallel to the longitudinal axis, the second internal assembly being configured to engage a plurality of insert members of one or more plug-in units, and wherein the first internal assembly and the second internal assembly are electrically coupled.

[0084] Clause 22. The high-current busbar assembly as described in Clause 21, wherein each of the plurality of insert components has a rated current of 800A or higher.

[0085] Clause 23. The high-current busbar assembly as described in Clause 21, wherein the outer components are formed of extruded aluminum.

[0086] Clause 24. The high-current busbar assembly as described in Clause 23, wherein the first and second internal components are formed of aluminum or copper strip material.

[0087] Clause 25. The high-current busbar assembly as described in Clause 24, wherein the thickness of the copper strip material ranges from 0.030 inches to 0.065 inches.

[0088] Clause 26. The high-current busbar assembly as described in Clause 23, wherein the first internal assembly and the second internal assembly are formed of aluminum.

[0089] Clause 27. A high-current busbar trunking system, comprising: a main busbar; and a continuous access busbar trunking system horizontally adjacent to the main busbar.

[0090] Clause 28. A high-current distribution rail, comprising: an elongated metal housing; an elongated first rail segment located within the elongated metal housing, the elongated first rail segment being configured to carry a high current; and an elongated second rail segment located within the elongated metal housing and electrically coupled to the elongated first rail segment, wherein the elongated second rail segment is configured to engage a plug unit, and wherein the plug unit is configured to provide a high current to one or more devices electrically coupled to the plug unit.

[0091] Clause 29. The high-current distribution rail as described in Clause 28, wherein the elongated metal housing is formed from extruded aluminum.

[0092] Clause 30. The high-current distribution rail as described in Clause 28, wherein an elongated second rail segment is electrically coupled to an elongated first rail segment via one or more conductive connector busbars.

[0093] Clause 31. A high-current distribution rail as described in Clause 28, wherein an elongated first rail segment is physically connected to an elongated second rail segment.

[0094] Clause 32. High-current busbar trunking as shown and described in this patent document.

Claims

1. A high-current busbar assembly, the assembly comprising: First conductor assembly; Two or more busbar trunks, wherein each of the two or more busbar trunks is a distribution busbar or a transmission busbar, wherein each of the two or more busbar trunks is electrically connected at a first end to the first conductor assembly; and The second conductor assembly, wherein each of the two or more busbar trunks is electrically connected to the second conductor assembly at a second end of each of the two or more busbar trunks.

2. The component according to claim 1, wherein, The two or more busbar trunks are connected in parallel to each other.

3. The component according to claim 1, wherein, Each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

4. The component according to claim 1, wherein, Each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

5. The component according to claim 1, wherein, At least one of the two or more busbar trunk lines is a distribution busbar.

6. The component according to claim 5, wherein, The power distribution bus is an open-type trough-type power distribution trunk line.

7. The component of claim 5, further comprising one or more power supply units attached to the distribution bus between the first conductor assembly and the second conductor assembly.

8. The component of claim 1, further comprising one or more connector adapter pieces for connecting the first conductor assembly to the two or more busbars.

9. The component according to claim 1, wherein, At least one of the first conductor assembly and the second conductor assembly is attached to another busbar assembly.

10. The component of claim 1, wherein, The rated current of the component is at least 1600A.

11. A method for manufacturing a high-current busbar assembly, the method comprising: Provide the first conductor assembly; Two or more busbar trunks are electrically connected to the first conductor assembly, wherein each of the two or more busbar trunks is a distribution busbar or a transmission busbar, and wherein each of the two or more busbar trunks is electrically connected to the first conductor assembly at a first end; and The second conductor assembly is electrically connected to the two or more busbars, wherein each of the two or more busbars is electrically connected to the second conductor assembly at a second end of each of the two or more busbars.

12. The method according to claim 11, wherein, The two or more busbar trunks are connected in parallel to each other.

13. The method according to claim 11, wherein, Each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

14. The method according to claim 11, wherein, Each of the first conductor assembly and the second conductor assembly is sized to accommodate two busbar trunks.

15. The method according to claim 11, wherein, At least one of the two or more busbar trunk lines is a distribution busbar.

16. The method according to claim 15, wherein, The power distribution bus is an open-type trough-type power distribution trunk line.

17. The method of claim 15, further comprising attaching one or more power supply units to the distribution bus between the first conductor assembly and the second conductor assembly.

18. The method of claim 11, further comprising connecting one or more connector adapter pieces to the first conductor assembly for connection to the two or more busbars.

19. The method according to claim 11, wherein, At least one of the first conductor assembly and the second conductor assembly is attached to another busbar assembly.

20. The method according to claim 11, wherein, The rated current of the component is at least 1600A.

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