Busbar Insulation Design for Flashover Prevention

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Solution Overview

Problem

In high-power power converters, the compact arrangement of busbars with different potentials increases the risk of voltage flashovers due to insufficient clearance and creepage distances, leading to electrical losses and reduced efficiency.

Innovation Solution

A device with an insulating means having specific openings that overlap with busbar openings, allowing for reduced distances between busbars while maintaining sufficient creepage distances to prevent voltage flashovers, and optionally incorporating mechanical fasteners and beads for enhanced insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If busbars are positioned close together to save space, then the device becomes more compact, but the risk of voltage flashover increases due to insufficient clearance and creepage distances

Engineering Contradiction:

Improvedevice volumeVSAvoidvoltage flashover risk

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The insulating element is inserted into the insulation space between the busbars, with insulating openings that receive and nest the connection elements. This nested arrangement allows compact positioning of busbars while maintaining proper insulation distances, resolving the contradiction between compactness and flashover prevention.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

An insulating element acts as an intermediary component between the first and second busbars. This mediator provides the necessary electrical isolation while allowing the busbars to be positioned close together, enabling both compact device volume and reliable electrical insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If oversized openings are made in busbars to accommodate insulating elements, then voltage flashover is prevented, but the conductivity of busbars is weakened and electrical resistance increases

Engineering Contradiction:

Improvevoltage flashover preventionVSAvoidelectrical losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The insulating element provides electrical isolation only at the specific locations where connection elements pass through, rather than requiring oversized openings that would weaken the entire busbar. This localized insulation approach prevents flashovers while maintaining the structural integrity and conductivity of the busbars.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insulating element is a simple, replaceable component that provides the necessary insulation function without requiring permanent modification of the busbars. This allows standard-sized busbar openings to be used, maintaining busbar conductivity while achieving flashover prevention through the removable insulating element.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If connection elements are made larger to ensure proper electrical connection, then connection reliability is improved, but the required insulation space increases and device compactness is reduced

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddevice volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The connection elements are inserted through the insulating element's openings, creating a nested arrangement where the connection element passes through the insulating material. This allows proper electrical connection to be achieved without requiring excessive insulation space, maintaining device compactness while ensuring reliable connections.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP3459170B1Device for the electrical connection of at least one electrical component with a first and a second busbar

Publication Date: 2020.03.25 SIEMENS AG

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AI summary

Apparatus for electrically connecting at least one electrical component to a first and second busbar The invention relates to an apparatus (VO) for electrically connecting at least one electrical component (BE) to a first and second busbar (1, 2), which busbars have a different potential (P+, P-) to one another during electrical operation, wherein an insulation means (9) is arranged between the first and the second busbar (1, 2) and has a first and second insulation means opening (10, 11), wherein the first busbar (1) has a first busbar opening (3), intended to be a first electrical connection (4), and a second busbar opening (5), wherein the second busbar (2) has a third busbar opening (6), intended to be a second electrical connection (7), and a fourth busbar opening (8), wherein the first insulation means opening (10), the first busbar opening (3) and the fourth busbar opening (8) overlap, and wherein the second insulation means opening (11), the third busbar openings (6) and the second busbar openings (5) overlap. The insulation means (9) has a first opening boundary (12) of the first insulation means opening (10), which opening boundary projects into the fourth busbar opening (8) of the second busbar (2), and the insulation means (9) has a second opening boundary (13) of the second insulation means opening (11), which opening boundary projects into the second busbar opening (5) of the first busbar (1). The invention further relates to a converter (24) which comprises the apparatus (VO).