Overlapping Busbar Insulation Layout for Low-Inductance Connections
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Solution Overview
Problem
Existing apparatuses with closely spaced busbars of different potentials risk short circuits due to insufficient air gaps and leakage paths, and insulation in bonded connections is not feasible due to temperature constraints, leading to increased inductance and reduced efficiency.
Innovation Solution
The apparatus features overlapping busbars with partial radial spacing and strategically placed insulation elements, including an electrically insulating film and moulded component, to maintain safety and reduce inductance while allowing for efficient electrical connections through positive-locking or bonded connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If busbars are arranged with small spacing to reduce inductance, then efficiency is improved, but the risk of short circuit increases due to insufficient air gaps and leakage paths
Solution Approach 1:
The insulation system is segmented into multiple insulation elements arranged between the busbars, creating multiple discrete insulation barriers rather than a single continuous insulation layer. This segmentation allows the busbars to be positioned closer together while maintaining adequate insulation through the combined effect of multiple insulation elements.
Solution Approach 2:
Insulation elements are introduced as intermediary components between the first and second busbars. These insulation elements serve as mediators that enable the busbars to be positioned with small spacing while preventing electrical breakdown, thus resolving the conflict between reducing inductance and preventing short circuits.
2Reliability
If insulation means are installed between busbars to prevent voltage flashover, then reliability is improved, but inductance increases and efficiency decreases
Solution Approach 1:
The insulation elements are positioned locally at critical regions where voltage flashover is most likely to occur, rather than providing uniform insulation throughout. This localized insulation approach prevents voltage flashover at critical points while minimizing the overall impact on inductance by allowing busbars to overlap in non-critical regions.
3Ease of manufacture
If busbars are arranged remotely to maintain air gaps and leakage paths without insulation, then insulation feasibility is improved, but inductance increases and efficiency is reduced
Solution Approach 1:
The insulation elements extend in the axial direction between the busbars, utilizing the third dimension (axial spacing) to provide insulation rather than relying solely on radial spacing. This dimensional approach allows the busbars to be positioned closer in the radial direction (reducing inductance) while maintaining adequate insulation through axial extension of the insulation elements.
Data Source
AI summary
An apparatus for providing an electrical connection to at least one electrical component comprising a first busbar, a second busbar, wherein during the electrical operation the first busbar and the second busbar have a different potential with respect to one another and are arranged parallel to one another, a first insulation element and a second insulation element. The first insulation element and the second insulation element overlap in part in an axial direction but are arranged spaced from one another in the radial direction at least in part between the first busbar and the second busbar. In addition, at least the first busbar has a contacting means for providing an electrical contact to an electrical component, wherein the second insulation element is arranged in the region of the contacting means.