Small busbar assembly

Abstract

A busbar assembly is disclosed that includes a carrier and a plurality of conductors disposed within the carrier such that at least a portion of each of the plurality of conductors is radially exposed to define a contact site.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Nonprovisional Patent Application No. 17 / 152,112, filed January 19, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present disclosure relates to a busbar assembly. [Background technology]

[0003] An electric motor generally includes a stator, a rotor, and other components. One such component is a busbar or contact carrier that provides an electrical interface with the stator. Based on the different shapes and sizes of electric motors, the busbar can take on a variety of shapes, sizes, and configurations.

[0004] There is a general desire to provide more efficient electric motor designs, as well as designs that are small in size and relatively easy to manufacture cost-effectively. Summary of the Invention [Means for solving the problem]

[0005] A busbar assembly is disclosed that includes a carrier and a plurality of conductors disposed within the carrier such that at least a portion of each of the plurality of conductors is radially exposed and defines an electrical contact site. The carrier may be formed by molding the carrier around the plurality of conductors.

[0006] The conductors can include a first phase conductor, a second phase conductor, a third phase conductor, and a neutral conductor. The first conductor and the second conductor can be disposed in a first axial plane extending perpendicular to the axis of the carrier, and the third conductor and the neutral conductor can be disposed in a second axial plane extending perpendicular to the axis of the carrier.

[0007] The first phase conductor, the second phase conductor, the third phase conductor, and the neutral conductor each define a predetermined number of electrical contact sites, with the neutral conductor having more electrical contact sites than the other conductors.

[0008] In one embodiment, the neutral conductor is positioned such that a contact point of the neutral conductor is defined radially inward of the carrier.

[0009] The carrier can include a plurality of retainers, each sized or configured to hold an electrical wire. The retainers are disposed along at least one of the radially inner or outer surfaces of the carrier. The plurality of retainers includes a first set of retainers defining radially oriented slots and a second set of retainers defining circumferentially oriented slots.

[0010] In one aspect, the conductors each have a square outline.

[0011] Additional embodiments are disclosed herein.

[0012] The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the accompanying drawings illustrating preferred embodiments of the present disclosure. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view of a busbar assembly through a cross section of the busbar assembly according to one embodiment. [Diagram 2] FIG. 2 illustrates the busbar assembly of FIG. 1 with a stator assembly mounted thereon. [Diagram 3] FIG. 2 is a perspective view of the busbar assembly of FIG. 1. [Figure 4] FIG. 2 is a front cross-sectional view of the busbar assembly of FIG. 1. [Diagram 5] 2 is a top cross-sectional side view of the busbar assembly of FIG. 1. [Figure 6]FIG. 2 is a perspective view of a busbar assembly including a wire retainer. [Figure 7] FIG. 7 is a front cross-sectional view of the busbar assembly of FIG. [Figure 8] 8 is another cross-sectional elevation view of the busbar assembly of FIG. 6 in a different region than that shown in FIG. 7. [Figure 9] FIG. 7 shows the busbar assembly of FIG. 6 mounted with a stator assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] In the following description, certain terminology is used for convenience only and is not limiting: "Axially" refers to a direction along the axis (X) of the assembly; "Radially" refers to a direction inward and outward from the axis (X) of the assembly; "Circumferentially" refers to a direction extending along the curvature or periphery of each element relative to the axis (X) of the assembly.

[0015] Reference to a list of items cited as "at least one of a, b, or c," where a, b, and c represent the items listed, means any one of items a, b, or c, or any combination thereof. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import.

[0016] As shown in the figures, there is disclosed a busbar assembly 10. The busbar assembly generally includes a carrier 12 and a number of conductors 20, 30, 40, 50 disposed within the carrier 12.

[0017] The carrier 12, also known as the insulator, is formed around each of the plurality of conductors 20, 30, 40, 50 such that at least a portion of each of the plurality of conductors 20, 30, 40, 50 is exposed (i.e., not fully encapsulated). The carrier 12 may be molded, i.e., overmolded, around the conductors or may be otherwise formed such that the carrier 12 encases or covers most of the conductors. In another aspect, the insulator or carrier may be formed as a tray-style configuration in which the carrier is separately formed or fabricated prior to the addition or bonding of any conductors. The conductors may be placed or installed within channels defined by the already formed carrier. The exposed portions of the conductors 20, 30, 40, 50 define electrical contact sites 22, 32, 42, 52, also known as contact pads. In one aspect, the configuration is asymmetrical since no additional phase terminals need to be added to the conductors 20, 30, 40, 50. As used herein, the term asymmetrical with respect to the configuration means that the input current arrives at the conductor at the terminal (i.e., the locations indicated by reference numerals 24, 34, and 44) ​​and travels the entire length of the conductor to reach the final contact location. Conversely, a symmetrical arrangement requires that the input current and contact location be equally divided on either side of the terminal location. Thus, in a symmetrical arrangement, there is a symmetric amount of current provided to a symmetric amount of windings on either side of the terminal location.

[0018] As shown in FIG. 4, the electrical contact sites 22, 32, 42, 52 may be formed by portions of the conductors 20, 30, 40, 50 being bent or deviated from a generally circular profile to vary slightly in either a radially outward or radially inward direction to define the electrical contact sites 22, 32, 42, 52.

[0019] In one embodiment, the plurality of conductors includes a first phase conductor 20, a second phase conductor 30, a third phase conductor 40, and a neutral conductor 50. For example, the three phases may correspond to a U phase, a V phase, and a W phase. One of ordinary skill in the art will recognize based on this disclosure that the number of phases and the configuration of conductors may vary.

[0020] In one embodiment, the conductors 20, 30, 40, 50 each have a square profile when viewed in the circumferential direction. Those skilled in the art will appreciate that the shape of the conductors 20, 30, 40, 50 may vary and may be circular or any other shape.

[0021] 5, the first conductor 20 and the second conductor 30 are disposed in a first axial plane P1 extending perpendicular to the axis (X) of the carrier 12, and the third conductor 40 and the neutral conductor 50 are disposed in a second axial plane P2 extending perpendicular to the axis (X) of the carrier 12. In other words, the first set of conductors (i.e., the first conductors 20 and the second conductors 30) are radially stacked on top of each other, and the second set of conductors (i.e., the third conductors 40 and the neutral conductor 50) are axially spaced or offset from the first set of conductors and radially stacked on top of each other.

[0022] The first phase conductor 20, the second phase conductor 30, the third phase conductor 40, and the neutral conductor 50 each define a predetermined number of electrical contact sites 22, 32, 42, 52. In one embodiment, the predetermined number of electrical contact sites 52 on the neutral conductor 50 is greater than the predetermined number of electrical contact sites on any of the first phase conductor 20, the second phase conductor 30, or the third phase conductor 40. One skilled in the art will recognize that the number of electrical contact sites 22, 32, 42, 52 may vary. In another embodiment, the number of neutral contact sites 52 may be equal to the sum of all the numbers of contact sites 22, 32, 42 on the other phase conductors.

[0023] In one aspect, the neutral conductor 50 is positioned such that the contact 52 of the neutral conductor 50 is defined on the radially inner surface 14 of the carrier 12. This configuration can be modified such that the neutral conductor contact 52 is defined on the radially outer surface 16 of the carrier 12.

[0024] The stator assembly is generally shown in Figures 2 and 9, which show wires or windings 70 configured to engage electrical contact sites 22, 32, 42, 52 of conductors 20, 30, 40, 50. When fully assembled, wires 70 are connected to electrical contact sites 22, 32, 42, 52 of conductors 20, 30, 40, 50. For example, connections between these elements may be made by laser welding, silver soldering, resistance welding, or any other form of connection.

[0025] Each of the conductors 20, 30, 40, 50 has a predetermined thickness (t), as shown in FIG. 5, and the carrier 12 has a total axial thickness (T A The entire busbar assembly 10 is axially constrained between a third axial plane (P3) and a fourth axial plane (P4).

[0026] In one embodiment, the thickness (t) of the conductor is the total axial thickness (T A In another embodiment, the thickness (t) of the conductor is less than 40% of the overall axial thickness (T A ) is 25% to 45% of the thickness (t) of the conductor. In one embodiment, the thickness (t) of the conductor is a function of the application and current requirements, as well as any manufacturing requirements.

[0027] Based on the conductors 20, 30, 40, 50 having a square profile (at least in the region away from the contacts), the thickness (t) of the conductors 20, 30, 40, 50 is the same in the radial and axial directions. As shown in FIG. 5, in one embodiment, the total radial thickness (T R ) is also predefined for the carrier 12, and the thickness (t) of the conductor is determined by the total radial thickness (T R In another embodiment, the thickness (t) of the conductor is less than 40% of the total radial thickness (T R In one embodiment, the thickness (T A ) and (T R ) is a function of thickness (t) and electrical insulation requirements.

[0028] Those skilled in the art will appreciate that the dimensions of the carrier 12 and conductors 20, 30, 40, 50 may vary. The present disclosure generally provides for configurations of the busbar assembly 10 that are axially and radially small in size.

[0029] As shown in Figure 2, the ends 24, 34, 44 of the first, second, and third conductors 20, 30, 40 may include terminals 25, 35, 45. The ends 24, 34, 44 of the first, second, and third conductors 20, 30, 40 extend completely radially and extend radially outward from the carrier 12. In one aspect, the terminals may be made or formed from the conductors themselves. In other words, a separate termination component or element may not be required.

[0030] As shown in Figures 6-9, the carrier can include a plurality of retainers 60 each configured or dimensioned to hold the wire 70 in place. In one aspect, the retainers are configured to hold the wire 70 in place during manufacturing or assembly. The carrier 12 of Figures 6-9 is otherwise identical to the carrier 12 of Figures 1-5. The retainers 60 can be formed in a variety of configurations and shapes and can be located at a variety of locations along the carrier 12. In one aspect, the plurality of retainers 60 are disposed along at least one of the radially inner surface 14 or the radially outer surface 16 of the carrier 12. In one embodiment, the retainers 60 are provided on both the radially inner surface 14 and the radially outer surface 16 of the carrier 12.

[0031] In one aspect, the plurality of retainers 60 includes a first set of retainers 62 defining radially oriented slots 64 and a second set of retainers 66 defining circumferentially oriented slots 68. As one of ordinary skill in the art would understand based on this disclosure, the specific shape, location, and quantity of the retainers 60 can vary. As shown in the drawings, the retainers 60 each circumferentially overlap at least one of the electrical contact sites 22, 32, 42, 52. In one aspect, the retainers 60 are positioned immediately adjacent to two electrical contact sites in the circumferential direction and immediately adjacent to another electrical contact site in the axial direction (as shown in FIG. 9). In other words, the retainers 60 can be positioned such that they are surrounded on at least three sides by the electrical contact sites.

[0032] Having thus described the present disclosure in detail, it will be understood, and will be apparent to those skilled in the art, that numerous physical modifications, only a few of which are illustrated in the detailed description of the embodiments, can be made without altering the concepts and principles of the present invention embodied therein.

[0033] It should also be understood that many embodiments are possible that incorporate only portions of the preferred embodiment and that, with respect to those portions, do not change the concepts and principles of the present invention embodied therein.

[0034] The present embodiments and optional configurations are therefore considered in all respects to be illustrative and / or explanatory and not restrictive, the scope of the embodiments being indicated by the appended claims rather than the foregoing description, and all alternative embodiments and modifications to the present embodiments that come within the meaning and range of equivalents of the claims are therefore intended to be embraced therein. [Explanation of symbols]

[0035] 10 Busbar Assembly 12. Career 14 Radial inner surface of carrier 16 Radial outer surface of carrier 20 First phase conductor 22 First phase conductor electrical contact portion 24 First phase conductor end 25 First phase conductor terminal 30 Second phase conductor 32 Second phase conductor electrical contact area 34 Second phase conductor end 35 Second phase conductor terminal 40 Third phase conductor 42 Third phase conductor electrical contact area 44 Third phase conductor end 45 Third phase conductor terminal 50 Neutral conductor 52 Neutral conductor electrical contact 60 Retainer 62 First set of retainers 64 Slots 66 Second set of retainers 68 Slots 70 Wire

Claims

1. A substantially circular carrier; a plurality of conductors arranged in an arc within the carrier, at least a portion of each of the plurality of conductors being radially exposed from the carrier to define a contact site; Including, A busbar assembly, wherein the contact locations are formed by the sides of the conductors that protrude radially from the carrier as a result of arcuate portions of the conductors deforming in either a radially outward or radially inward direction.

2. The busbar assembly of claim 1 , wherein the plurality of conductors includes a first phase conductor, a second phase conductor, a third phase conductor, and a neutral conductor.

3. The busbar assembly of claim 2 , wherein the first phase conductor and the second phase conductor are disposed in a first axial plane extending perpendicular to an axis of the carrier.

4. 4. The busbar assembly of claim 3, wherein the third phase conductor and the neutral conductor are disposed in a second axial plane extending perpendicular to the axis of the carrier, the second axial plane being offset from the first axial plane.

5. the first phase conductor, the second phase conductor, the third phase conductor, and the neutral conductor each define a predetermined number of contact sites; 3. The busbar assembly of claim 2, wherein the predetermined number of contact sites on the neutral conductor is greater than the predetermined number of contact sites on any of the first phase conductor, the second phase conductor, or the third phase conductor.

6. The busbar assembly of claim 2 , wherein the neutral conductor is positioned such that the contact site of the neutral conductor is defined on a radially inner surface of the carrier.

7. The busbar assembly of claim 1 , wherein the carrier is formed by molding the carrier around the plurality of conductors.

8. The busbar assembly of claim 1 , wherein the carrier includes a plurality of retainers, each of the plurality of retainers being dimensioned to hold an electrical wire.

9. The busbar assembly of claim 8 , wherein the plurality of retainers are disposed along at least one of a radially inner surface or a radially outer surface of the carrier.

10. 9. The busbar assembly of claim 8, wherein the plurality of retainers includes a first set of retainers defining radially oriented slots and a second set of retainers defining circumferentially oriented slots.

11. The busbar assembly of claim 1 , wherein each of the plurality of conductors has a square cross-sectional profile.

12. 2. The busbar assembly of claim 1, wherein a first set of two conductors of the plurality of conductors overlap one another in a radial direction, and a second set of two conductors of the plurality of conductors are axially spaced from the first set of two conductors and overlap one another in the radial direction.

13. 2. The busbar assembly of claim 1, wherein each of the plurality of conductors has a predetermined axial thickness (t) and the carrier has a total axial thickness (T), the predetermined axial thickness (t) being less than 40% of the total axial thickness (T).

14. The busbar assembly of claim 1 , wherein at least one end of at least three conductors of the plurality of conductors extends radially outward from the carrier.

15. A plurality of conductors arranged in an arc, a first set of two conductors of the plurality of conductors radially overlapping one another; a second set of two conductors from the plurality of conductors axially spaced from the first set of two conductors and overlapping each other in the radial direction; a generally circular carrier molded around the plurality of conductors such that a portion of the plurality of conductors is exposed at a radially inner surface of the carrier and at a radially outer surface of the carrier to define electrical contact sites; Including, A busbar assembly, wherein the electrical contact locations are formed by the sides of the conductors that protrude radially from the carrier as a result of arcuate portions of the conductors deforming in either a radially outward or radially inward direction.

16. The busbar assembly of claim 15 , wherein each of the plurality of conductors has a square cross-sectional profile.

17. The busbar assembly of claim 15 , wherein the carrier includes a plurality of retainers, each of the plurality of retainers being dimensioned to hold an electrical wire.

18. The busbar assembly of claim 17 , wherein the plurality of retainers are disposed along at least one of a radially inner surface or a radially outer surface of the carrier.

19. The busbar assembly of claim 17 , wherein each of the plurality of retainers circumferentially overlaps at least one contact site of the plurality of conductors.

20. The busbar assembly of claim 15 , wherein at least one end of at least three conductors of the plurality of conductors extends radially outward from the carrier.

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