Low inductance busbar systems and methods

Abstract

An electrical system includes a power electronics system and a bus bar coupled to the power electronic system. The power electronics system includes a switching device configured to selectively connect and disconnect. The bus bar includes a first conductive layer and a second conductive layer. The first conductive layer is disposed directly adjacent a first insulation layer, wherein the first conductive layer is configured to conduct a first polarity of electrical power to, from, or both the power electronics system. The second conductive layer is disposed directly adjacent the first insulation layer, and is configured to conduct a second polarity of electrical power opposite the first polarity to, from, or both the power electronics system. The first conductive layer comprises a first thickness half a second thickness of the second conductive layer.

1 . An electrical system, comprising:
 a power electronics system comprising a switching device, wherein the switching device is configured to selectively connect and disconnect;   a bus bar electrically coupled to the power electronics system, wherein the bus bar comprises:
 a first conductive layer disposed directly adjacent a first insulation layer, wherein the first conductive layer is configured to conduct a first polarity of electrical power to, from, or both the power electronics system; and 
 a second conductive layer disposed directly adjacent the first insulation layer, wherein the second configured to conduct a second polarity of electrical power opposite the first polarity to, from, or both the power electronics system; 
 wherein the first conductive layer comprises a first thickness half a second thickness of the second conductive layer. 
   
     
     
         2 . The electrical system of  claim 1 , wherein the bus bar comprises a third conductive layer disposed directly adjacent a second insulation film, wherein:
 the third conductive layer is configured to conduct the first polarity of electrical power to, from, or both the power electronics system in parallel with the first conductive layer; and   the third conductive layer comprises the second thickness.   
     
     
         3 . The electrical system of  claim 2 , wherein the bus bar comprises:
 a fourth conductive layer disposed directly adjacent a third insulation layer and directly adjacent a fourth insulation layer disposed directly adjacent the second conductive layer, wherein:
 the fourth conductive layer is configured to conduct the first polarity of electrical power to, from, or both the power electronics system in parallel with the first conductive layer and the third conductive layer; and 
 the fourth conductive layer comprises the second thickness; and 
   a fifth conductive layer disposed directly adjacent the second insulation layer and directly adjacent the third insulation layer, wherein:
 the fifth conductive layer is configured to conduct the second polarity of electrical power to, from, or both the power electronics system in parallel with the second conductive layer; and 
 the fifth conductive layer comprises the first thickness. 
   
     
     
         4 . The electrical system of  claim 2 , wherein the second conductive layer is disposed directly adjacent the second insulation layer. 
     
     
         5 . The electrical system of  claim 1 , comprising a capacitor coupled to an exterior surface of the bus bar, wherein the capacitor comprises:
 a first terminal electrically connected to the first conductive layer; and   a second terminal electrically connected to the second conductive layer.   
     
     
         6 . The electrical system of  claim 5 , comprising:
 a first fastener that extends through the bus bar to:
 secure the capacitor to the exterior surface of the bus bar; 
 electrically connecting the first terminal to the first conductive layer; and 
 electrically isolate the first terminal from the second conductive layer; and 
   a second fastener that extends through the bus bar to:
 secure the capacitor to the exterior surface of the bus bar; 
 electrically connecting the second terminal to the second conductive layer; and 
 electrically isolate the first terminal from the first conductive layer. 
   
     
     
         7 . The electrical system of  claim 1 , wherein the first insulation layer comprises a third thickness. 
     
     
         8 . The electrical system of  claim 1 , wherein the bus bar is configured to:
 enable the power electronics system to supply electrical power to an electrical load;   enable the power electronics system to receive electrical power from a power source; or   both.   
     
     
         9 . The electrical system of  claim 1 , wherein the power electronics system is configured to selectively connect and disconnect the switching device to facilitate converting input electrical power into output electrical power. 
     
     
         10 . The electrical system of  claim 1 , wherein the electrical system comprises an industrial system, a manufacturing system, an automation system, a computing system, an automotive system, or any combination thereof. 
     
     
         11 . A method of manufacturing a bus bar used to electrically connect one or more electrical components, comprising:
 coupling a first insulating layer to a first side of an interior layer, wherein the interior layer comprises a first thickness;   coupling a second insulating layer to a second side of the interior layer;   coupling a first intermediate layer to the second insulating layer, wherein the first intermediate layer comprises the first thickness;   coupling a second intermediate layer to the first insulating layer, wherein the second intermediate layer comprises the first thickness;   coupling a third insulating layer to the first intermediate layer;   coupling a fourth insulating layer to the second intermediate layer;   coupling a first external layer to the third insulating layer, wherein the first external layer comprises a second thickness different from the first thickness; and   coupling a second external layer to the fourth insulating layer, wherein the second external layer comprises the second thickness.   
     
     
         12 . The method of  claim 11 , wherein the first thickness is twice the second thickness. 
     
     
         13 . The method of  claim 11 , comprising:
 electrically connecting the interior layer, the first external layer, and the second external layer in parallel; and   electrically connecting the first intermediate layer and the second intermediate layer in parallel.   
     
     
         14 . The method of  claim 11 , comprising:
 forming a first hole through the bus bar to facilitate securing a capacitor to the bus bar and electrically connecting a first terminal of the capacitor to the interior layer, the first external layer, and the second external layer; and   forming a second hole the bus bar to facilitate securing the capacitor to the bus bar and electrically connecting a second terminal of the capacitor to the first intermediate layer and the second intermediate layer.   
     
     
         15 . The method of  claim 11 , wherein:
 forming the first hole comprises:
 forming the first hole with a first diameter in the interior layer, the first external layer, and the second external layer; and 
 forming the first hole with a second diameter greater than the first diameter in the first intermediate layer and the second intermediate layer; and 
   forming the second hole comprises:
 forming the second hole with the second diameter in the interior layer, the first external layer, and the second external layer; and 
 forming the second hole with first diameter in the first intermediate layer and the second intermediate layer.