Laminated Busbar Coupling With Integrated Circuit Breaker Terminals

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Solution Overview

Problem

Existing laminated busbar systems lack effective overcurrent protection when connecting multiple busbars, leading to a risk of damage from short circuits, and require additional space-consuming equipment for circuit breaker mounting.

Innovation Solution

A coupling element with a base body of conducting layers and insulating layers that includes circuit breaker terminals for each busbar section, allowing for electrical insulation and overcurrent protection between busbars, with cylindrical pins and L/T-shaped terminal members for flexible mounting and even current distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If circuit breakers are connected to laminated busbars using separate flat copper bars, then electrical connection is achieved, but additional space-consuming mounting equipment is required

Engineering Contradiction:

Improveelectrical connectionVSAvoidmounting equipment space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The coupling element merges multiple functions into a single integrated component: it provides mechanical coupling between busbars, electrical connection through conducting layers, and circuit breaker mounting through integrated terminal members. This eliminates the need for separate flat copper bars and mounting equipment, directly resolving the space consumption problem while maintaining reliable electrical connection

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupling element serves multiple purposes simultaneously: it acts as a mechanical connector for busbars, an electrical conductor through its conducting layers, and a mounting structure for circuit breakers via integrated terminal members. This multi-functionality replaces multiple separate components, reducing the overall space required for mounting equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If multiple busbars are connected without overcurrent protection, then electrical coupling is achieved, but damage risk from short circuits increases

Engineering Contradiction:

Improveelectrical coupling efficiencyVSAvoidshort circuit damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The coupling element acts as an intermediary between multiple busbars, incorporating circuit breaker terminals that can accommodate circuit breakers. These circuit breakers serve as protective intermediaries that detect and interrupt overcurrent conditions, preventing short circuit damage from propagating between busbars while maintaining efficient electrical coupling

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coupling element is designed with integrated circuit breaker terminals that enable pre-installation of protective circuit breakers. This beforehand preparation allows circuit breakers to be in place before short circuit events occur, providing protective cushioning against potential damage from overcurrent and short circuit conditions

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If conducting layers are directly connected without insulation, then electrical conductivity is improved, but thermal load and damage risk increase

Engineering Contradiction:

Improveelectrical conductivityVSAvoidthermal load

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The coupling element uses a composite structure with alternating conducting layers and insulating layers. The conducting layers provide necessary electrical conductivity for current flow, while the insulating layers provide thermal and electrical isolation to reduce thermal load and prevent overheating, resolving the contradiction between conductivity and temperature management

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coupling element segments the conducting layers with insulating layers in between. This segmentation creates distinct conductive paths while providing thermal and electrical isolation, allowing electrical conductivity where needed while reducing thermal load through the insulating barriers between conducting layers

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11843226B2Laminated busbars and direct connection of air circuit breakers in bus coupler sections

Publication Date: 2023.12.12 ABB (SCHWEIZ) AG

AI summary

A coupling element for electrically coupling a lateral connecting portion of a first laminated busbar to a lateral connecting portion of a second laminated busbar, the coupling element having a base body that includes a sandwich of conducting layers of sheet metal and intermediate insulating layers arranged in between the conducting layers for electrically insulating the conducting layers from each other. Each of the conducting layers includes a first layer section that is associated to the lateral connecting portion of the first busbar and a second layer section that is associated to the connecting portion of the second busbar. The first and second layer sections are electrically insulated from each other by an insulating element and each of the first layer sections includes a first circuit breaker connecting terminal that is adapted to be electrically connected to an input terminal of a circuit breaker.