High insulation composite busbar

Abstract

The utility model discloses a kind of high insulation composite busbar, including composite busbar body, composite busbar body includes several busbar conductive layers, adjacent busbar conductive layer between and the outside of busbar conductive layer are connected with insulating layer, composite busbar body includes incoming line area and outgoing line area, incoming line area and outgoing line area are equipped with the busbar connecting hole of through composite busbar body, busbar connecting hole is connected with busbar terminal column, busbar terminal column is only electrically connected with one layer busbar conductive layer;In incoming line area or outgoing line area, the busbar terminal column of different busbar conductive layer corresponding connection is equipped with insulating baffle between, insulating baffle is located the surface of outermost insulating layer;Incoming line area and outgoing line area are equipped with side connection area, the edge of busbar conductive layer is distributed and bent upwards to form several switching parts to side connection area, and the switching part between different busbar conductive layers is equipped with separation gap.The utility model effectively increases phase-to-phase creepage distance, reduces the creep risk between phase switching part.

Description

Technical Field

[0001] This utility model relates to the field of power connection technology, specifically to a high-insulation composite busbar. Background Technology

[0002] Composite busbars (also known as laminated busbars) are integrated electrical connection devices formed by alternating layers of conductive plates (such as copper or aluminum) and insulating materials (such as PET composite film, epoxy resin, etc.). They are integrally formed through a hot-pressing process, and the conductor layers are encapsulated by high-insulation-strength materials to form a composite structure with low inductance and low impedance. Compared with existing conventional wiring designs, this structure can save more than 30% of installation space and is suitable for high-density equipment layouts. It is widely used in high-voltage and high-current scenarios such as new energy inverters, rail transit traction systems, IGBT modules, and data center UPS.

[0003] Currently, the main defects in the electrical clearance of composite busbars are as follows: in pursuit of compactness, the stacking of multiple conductors in composite busbars may lead to a reduction in the electrical clearance between phases, which can easily cause arc discharge; and the structure of busbar connection holes, bent pins and other structures may cause electric field concentration. If the creepage distance is not increased through designs such as hollowing out or covering, partial discharge can easily occur at the defect.

[0004] In view of this, there is an urgent need to design a high-insulation composite busbar to overcome the technical defects of existing composite busbars. Utility Model Content

[0005] To address the aforementioned problems, this utility model provides a high-insulation composite busbar, comprising a composite busbar body, the composite busbar body including a plurality of busbar conductive layers, with insulating layers connecting adjacent busbar conductive layers and to the outer side of each busbar conductive layer. The composite busbar body includes an inlet area and an outlet area, both of which are provided with busbar connection holes penetrating the composite busbar body. Busbar terminals are connected within the busbar connection holes, and each busbar terminal is electrically connected to only one layer of the busbar conductive layer. In the inlet area or the outlet area, insulating baffles are provided between the corresponding busbar terminals connected to different busbar conductive layers, with the insulating baffles located on the outermost surface of the insulating layer. A side connection area is provided between the inlet area and the outlet area, and the edges of the busbar conductive layers are distributed and bent upward toward the side connection area to form a plurality of transition portions, with separation gaps provided between the transition portions of different busbar conductive layers.

[0006] In one possible implementation, the busbar terminal includes a contact portion and a penetrating portion, the contact portion of the busbar terminal is electrically connected to one of the busbar conductive layers, the penetrating portion of the busbar terminal passes through the other busbar conductive layers in sequence, and an annular isolation layer is provided between the penetrating portion and the other busbar conductive layers.

[0007] In one possible implementation, the size of the contact portion is larger than the size of the penetrating portion.

[0008] In one possible implementation, the annular insulating layer is a mica sheet, glass fiber reinforced polyester, or PI film.

[0009] In one possible implementation, the side of the outgoing area is provided with a plurality of backup power supply units, and the plurality of backup power supply units are respectively connected to the busbar conductive layer.

[0010] In one possible implementation, the thickness of the insulating strip is greater than the height at which the busbar terminal protrudes from the composite busbar body.

[0011] In one possible implementation, the incoming line area and the outgoing line area are parallel to each other, and the incoming line area and the outgoing line area are not on the same plane.

[0012] In one possible implementation, the adapter is connected to a screw-in threaded post.

[0013] In one possible implementation, the adapter is above the plane containing the incoming and outgoing cable areas.

[0014] In one possible implementation, the insulating strips are provided on both sides of the composite busbar body, and the insulating strips include alternating convex strips and grooves.

[0015] Compared with the prior art, the technical solution provided by this utility model has the following advantages: This technical solution for high-insulation composite busbars firstly divides the composite busbar body into incoming and outgoing sections. In both the incoming and outgoing sections, insulating strips are installed between the busbar terminals corresponding to different busbar conductive layers, effectively increasing the interphase creepage distance. This is especially important in high-voltage environments, preventing short circuits caused by insufficient electrical clearance. Secondly, in the side connection area, separation gaps are provided between the transition parts of different busbar conductive layers, expanding the electrical clearance between the interlayer transition parts and reducing the risk of creepage between phase transition parts.

[0016] In this technical solution, the edge of the busbar conductive layer bends upward toward the side connection area to form a transition section, and physical isolation is achieved through the separation gap. This transition design avoids electric field concentration near sharp structures such as connection holes and bent pins on the busbar conductive layer, thereby suppressing partial discharge and improving the safety of composite busbar use. Although the composite busbar increases insulation measures through structural layout and design, the main body structure of the composite busbar is still formed by multi-layer lamination, which saves installation space compared to existing conventional wiring. The design of the insulation strip and separation gap does not require a large amount of additional space, making it suitable for the layout of high-density power distribution equipment. Attached Figure Description

[0017] Figure 1 This is a perspective view of the composite busbar according to an embodiment of the present utility model.

[0018] Figure 2 This is another perspective view of the composite busbar according to an embodiment of the present utility model.

[0019] Figure 3 This is an exploded view of the composite busbar according to an embodiment of the present invention.

[0020] Figure 4 This is a perspective view of the composite busbar body according to an embodiment of the present utility model.

[0021] Figure 5 This is a partial cross-sectional view of the composite busbar according to an embodiment of the present invention.

[0022] Figure 6 This is a perspective view of the busbar terminals in an embodiment of the present utility model. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model. The accompanying drawings are for illustrative purposes only, representing schematic diagrams only, not actual object drawings, and should not be construed as limiting this patent. To better illustrate the embodiments of this utility model, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0024] Combined with appendix Figure 1 To be continued Figure 6This utility model provides a high-insulation composite busbar, comprising a composite busbar body 10. The composite busbar body 10 includes several busbar conductive layers 11. Insulation layers 12 are connected between adjacent busbar conductive layers 11 and to the outer side of each busbar conductive layer 11. The composite busbar body 10 includes an inlet area 13 and an outlet area 14. Both the inlet area 13 and the outlet area 14 are provided with busbar connection holes 15 penetrating the composite busbar body 10. Busbar terminals 20 are connected within the busbar connection holes 15. The busbar terminals 20 are only... It is electrically connected to the first layer of the busbar conductive layer 11; in the inlet area 13 or the outlet area 14, an insulating strip 30 is provided between the busbar terminals 20 connected to different busbar conductive layers 11, and the insulating strip 30 is located on the outermost surface of the insulating layer 12; a side connection area 16 is provided between the inlet area 13 and the outlet area 14, and the edges of the busbar conductive layers 11 are distributed and bent upward toward the side connection area 16 to form a plurality of transition parts 17, and a separation gap 18 is provided between the transition parts 17 of different busbar conductive layers 11.

[0025] In this embodiment, as shown in the accompanying drawings, the busbar conductive layer 11 is provided with two layers for single-phase power distribution. In another embodiment, the busbar conductive layer 11 may be provided with three or four layers for three-phase power distribution. It should be noted that the thickness of the insulating layer 12 between the busbar conductive layers 11 is greater than the thickness of the insulating layer 12 on the outside of the busbar conductive layer 11.

[0026] In one specific embodiment, the thickness of the insulating layer 12 between the busbar conductive layers 11 is 1.0mm-1.8mm, the thickness of the insulating layer 12 on the outside of the busbar conductive layers 11 is 0.5mm-1.0mm, and the insulating layer 12 can be made of glass fiber reinforced polyester or epoxy powder coating.

[0027] In this embodiment, the insulating strip 30 is connected to the surface of the composite busbar body 10 by heat fusion.

[0028] In this embodiment, the high-insulation composite busbar first divides the composite busbar body 10 into incoming and outgoing sections. In the incoming section 13 and the outgoing section 14, insulating strips 30 are provided between the busbar terminals 20 corresponding to the conductive layers 11 of different busbars, which effectively increases the creepage distance between phases, especially in high-voltage environments, to avoid short circuits caused by insufficient electrical clearance. Secondly, in the side connection section 16, a separation gap 18 is provided between the transition parts 17 of the conductive layers 11 of different busbars, which expands the electrical clearance between the interlayer transition parts 17 and reduces the creepage risk between the interphase transition parts 17.

[0029] In this embodiment, as shown in the appendix Figure 5 and attached Figure 6 As shown, the busbar terminal 20 includes a contact portion 21 and a penetrating portion 22. The contact portion 21 of the busbar terminal 20 is electrically connected to one of the busbar conductive layers 11. The penetrating portion 22 of the busbar terminal 20 passes through the other busbar conductive layers 11 in sequence, and an annular isolation layer 110 is provided between the penetrating portion 22 and the other busbar conductive layers 11.

[0030] In the above embodiment, the contact portion 21 is connected to the corresponding busbar conductive layer 11 by ultrasonic welding, and the annular isolation layer 110 is used for electrical insulation between the phase conductive layers.

[0031] In this embodiment, as shown in the appendix Figure 6 As shown, the size of the contact portion 21 is larger than the size of the penetrating portion 22, which facilitates a larger electrical connection area between the contact portion 21 and the corresponding busbar conductive layer 11, thereby improving the stability of the electrical connection.

[0032] In this embodiment, the annular insulating layer 110 is a mica sheet, glass fiber reinforced polyester, or PI film, and the above materials have good temperature resistance and insulation properties.

[0033] In this embodiment, as shown in the appendix Figure 2 As shown, the side of the outgoing area 14 is provided with a plurality of backup power taking parts 19, and the plurality of backup power taking parts 19 are respectively connected to the busbar conductive layer 11. The backup power taking parts 19 have similar functions to the adapter 17, but serve as backup power taking ends for electrical signals.

[0034] In this embodiment, as shown in the appendix Figure 5 As shown, the thickness of the insulating strip 30 is greater than the height of the busbar terminal 20 protruding from the composite busbar body 10.

[0035] In this embodiment, as shown in the appendix Figure 2 and attached Figure 4 As shown, the incoming line area 13 and the outgoing line area 14 are parallel to each other, and the incoming line area 13 and the outgoing line area 14 are not on the same plane. The parallel arrangement is beneficial to the electrical connection stability of the composite busbar in the application scenario.

[0036] In this embodiment, as shown in the appendix Figure 2 As shown, the adapter 17 is connected to a screw thread post 40 for electrical connection between the adapter 17 and the outside.

[0037] In this embodiment, the adapter 17 is higher than the plane containing the incoming line area 13 and the outgoing line area 14.

[0038] In this embodiment, as shown in the appendix Figure 5As shown, the insulating baffles 30 are provided on both sides of the composite busbar body 10. The insulating baffles 30 include alternating convex strips 31 and grooves 32.

[0039] In this embodiment, the edge of the busbar conductive layer 11 is bent upward toward the side connection area to form a transition part 17, and physical isolation is achieved through the separation gap 18. This transition design avoids the concentration of electric field at sharp structures such as connection holes and bent pins on the busbar conductive layer 11, thereby suppressing partial discharge and improving the safety of the composite busbar. Although the composite busbar has increased insulation measures through structural layout and design, the main body structure of the composite busbar is still formed by multi-layer lamination, which saves installation space compared with existing conventional wiring. The design of the insulating strip 30 and the separation gap 18 does not require a lot of extra space and is suitable for the layout of high-density power distribution equipment.

[0040] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating this utility model, and are not intended to limit the implementation of this utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model, or direct / indirect applications in other related technical fields, should be included within the scope of protection of the claims of this utility model.

Claims

1. A high-insulation composite busbar, comprising a composite busbar body, the composite busbar body comprising a plurality of busbar conductive layers, wherein an insulating layer is connected between adjacent busbar conductive layers and to the outside of each busbar conductive layer, characterized in that, The composite busbar body includes an inlet area and an outlet area. Both the inlet and outlet areas are provided with busbar connection holes that penetrate the composite busbar body. Busbar terminals are connected to the busbar connection holes, and each busbar terminal is electrically connected to only one layer of the busbar conductive layer. In the inlet or outlet area, insulating strips are provided between the busbar terminals connected to different busbar conductive layers. The insulating strips are located on the outermost surface of the insulating layer. A side connection area is provided between the inlet and outlet areas. The edges of the busbar conductive layers are distributed and bent upwards towards the side connection area to form several transition parts. Separation gaps are provided between the transition parts of different busbar conductive layers.

2. The high-insulation composite busbar according to claim 1, characterized in that, The busbar terminal includes a contact portion and a penetrating portion. The contact portion of the busbar terminal is electrically connected to one of the busbar conductive layers. The penetrating portion of the busbar terminal passes through the other busbar conductive layers in sequence, and an annular isolation layer is provided between the penetrating portion and the other busbar conductive layers.

3. The high-insulation composite busbar according to claim 2, characterized in that, The size of the contact portion is larger than the size of the penetrating portion.

4. A high-insulation composite busbar according to claim 2, characterized in that, The annular isolation layer is a mica sheet, glass fiber reinforced polyester, or PI film.

5. A high-insulation composite busbar according to claim 1, characterized in that, The side of the outgoing area is provided with several backup power supply units, and the several backup power supply units are respectively connected to the busbar conductive layer.

6. The high-insulation composite busbar according to claim 1, characterized in that, The thickness of the insulating strip is greater than the height at which the busbar terminal protrudes from the composite busbar body.

7. A high-insulation composite busbar according to any one of claims 1 to 6, characterized in that, The incoming line area and the outgoing line area are parallel to each other, but they are not on the same plane.

8. A high-insulation composite busbar according to any one of claims 1 to 6, characterized in that, The adapter is connected to a screw thread post.

9. A high-insulation composite busbar according to any one of claims 1 to 6, characterized in that, The adapter section is higher than the plane where the incoming line area and the outgoing line area are located.

10. A high-insulation composite busbar according to any one of claims 1 to 6, characterized in that, The insulating strips are provided on both sides of the composite busbar body. The insulating strips include alternating convex strips and grooves.

Images