Injection molding integrated busbar

Abstract

The invention relates to the technical field of busbars, in particular to an injection molding integrated busbar. The bus bar comprises three bus bars, a bus bar insulation shell, an injection molding shell boss and a first buckle, the bus bar insulation shell is arranged on the three bus bars, the bus bars are made of stainless steel copper-plated tin-plated materials, the bus bar insulation shell is integrally formed in an injection molding mode, the bus bar insulation shell is in close contact with the bus bars, the injection molding shell boss is arranged on the bus bar insulation shell, and the first buckle is arranged on the injection molding shell boss. A first threading hole is formed in the injection molding shell boss, the first buckle is arranged on the bus bar, and the first buckle extends out of the bus bar insulation shell. The bus bar and the insulating seat are tightly combined into a whole by adopting an injection molding integral forming technology, so that the hidden danger of looseness between the bus bar and the insulating seat in a traditional structure is eliminated, stable electrical connection can be kept even under an extreme operation condition, and current leakage and short circuit are effectively prevented.

Description

Technical Field

[0001] The present invention relates to the technical field of busbars, and in particular to an injection-molded integrated busbar. Background Art

[0002] In current motor design, the bus plays a vital role as a core component for connecting and distributing current. It is not only a bridge for current transmission between motor stator coils, but also has the important task of ensuring that current flows along a predetermined path and preventing short circuits.

[0003] The traditional motor bus structure is mainly composed of two parts: an insulating base and a bus bar. The insulating base is responsible for providing installation support and electrical isolation, while the bus bar is responsible for effectively connecting multiple windings of the motor stator to achieve centralized current distribution. Although this design meets the basic functional requirements to a certain extent, its limitations gradually emerge when facing complex operating environments and long-term use challenges. Traditional bus bars and insulating bases are mostly fixed by embedding or clamping. Although it is easy to assemble, it is easy to become loose due to external environmental impact or temperature changes inside the motor, resulting in reduced insulation performance and increased current leakage and short circuit risks. Although embedded assembly simplifies the installation steps of individual components, it has high requirements for assembly accuracy and consistency during mass production, which may affect overall production efficiency. Summary of the invention

[0004] In view of the problems existing in the background technology, an injection molded integrated busbar is proposed.

[0005] The present invention provides an injection-molded integrated busbar, comprising a busbar, a busbar insulating shell is arranged on the busbar, the busbar insulating shell is formed by injection molding, the busbar insulating shell is in close contact with the busbar, an injection-molded shell boss is arranged on the busbar insulating shell, a threading hole is opened on the injection-molded shell boss, a buckle is arranged on the busbar, the buckle extends to the outside of the busbar insulating shell, a threading hole is arranged on the buckle, the buckle is located directly above the injection-molded shell boss, and the threading hole is coaxially arranged with the threading hole; a stator lead head is passed through the injection-molded shell boss The wire is passed through the threading hole one, and then through the threading hole two on the clip one, and then the stator lead and the clip one are connected by welding; the corresponding three injection molding shell bosses are arranged in sequence of the lowest, the middle height, and the highest, and the bus bar heights are also arranged from low to high. The threading hole one on the injection molding shell boss is used to maintain the stability of the clip one and the stator lead during welding; there is a certain height distance between the bus bars. During the injection molding process of the busbar insulating shell, the busbar insulating shell will form a barrier between the bus bars, and there will be no contact between the bus bars after injection molding.

[0006] Preferably, the buckle one is integrally constructed, and a wire entry slot is provided on one side of the buckle one, and the wire entry slot is connected to the wire threading hole two on the buckle one.

[0007] Preferably, the buckle one is in a split structure, consisting of a fixed half buckle and a movable half buckle, the fixed half buckle is fixedly connected to the bus bar, the movable half buckle is arranged on one side of the fixed half buckle, the movable half buckle and the fixed half buckle are provided with an adjustment component for adjusting the distance between the movable half buckle and the fixed half buckle, and the movable half buckle and the fixed half buckle are provided with a buckle two for tightening the connection between the movable half buckle and the fixed half buckle.

[0008] Preferably, the adjustment assembly consists of two adjustment protrusions, two adjustment brackets and a limit block. The two adjustment protrusions are respectively installed on the movable half buckle and the fixed half buckle. The two adjustment brackets are respectively rotatably set on the two adjustment protrusions. The limit block is set above the movable half buckle and the fixed half buckle. The two adjustment brackets are rotatably connected to the limit block.

[0009] Preferably, buckle 2 is composed of a sub-buckle and a female buckle, the sub-buckle is installed on the fixed half buckle, and the female buckle is installed on the movable half buckle, and when the movable half buckle and the fixed half buckle are in contact with each other, the sub-buckle and the female buckle are in a clamping state.

[0010] Preferably, the threading holes one on the three injection-molded shell bosses of the same group are arranged in sequence as a through hole, a countersunk hole, and a countersunk hole, a fixing frame is arranged inside the threading hole one, a correction frame is arranged inside the fixing frame, a plurality of extrusion strips are installed on the correction frame, an extrusion frame is sleeved on the plurality of extrusion strips, and a lifting mechanism is arranged on the fixed frame for lifting the extrusion frame.

[0011] Preferably, the lifting mechanism includes a threaded rod rotatably mounted on a fixed frame, a gear transmission assembly is provided on the fixed frame, the gear transmission assembly is composed of gear one, gear two and gear three, gear one, gear two and gear three are meshed and connected with each other, a set of gears is provided on the threaded rod, a turning knob is provided on the fixed frame, one side of the turning knob extends outside the fixed frame and extends outside the injection molded shell boss, the turning knob is connected to gear three and is used to drive gear three to rotate.

[0012] Preferably, a limiting block is slidably installed in the fixed frame, a pull wire is provided on the limiting block, the other end of the pull wire is connected to the movable half buckle, one side of the limiting block is conically arranged, and the distance between the conical side and two adjacent racks on gear one is the same.

[0013] Preferably, the upper end of the correction frame is set to be a round hole shape, and the lower end is set to be a cone shape, which is used to correct the stator lead wire and facilitate guiding the stator lead wire head to pass through the threading hole one to reach the buckle one.

[0014] Preferably, the extruded strip is made of plastic material, and has a structure that is wide at the top and narrow at the bottom.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects: The present invention uses one-piece injection molding technology to tightly combine the bus bar and the insulating seat into a whole, eliminating the risk of looseness between the bus bar and the insulating seat in the traditional structure, and can maintain a stable electrical connection even under extreme operating conditions, effectively preventing current leakage and short circuit. At the same time, the one-piece injection molding design simplifies the assembly steps, reduces the number of parts and assembly errors, improves production efficiency and product quality consistency, and is particularly suitable for large-scale batch production.

[0016] The busbar of the present invention is made of stainless steel copper-plated tin-plated material, which not only has excellent electrical conductivity, but also can improve the heat dissipation efficiency to a certain extent, reduce the winding damage caused by the electrothermal effect, and extend the service life of the motor; By adopting a split-type structure of the first buckle, the width of the second threading hole can be increased, which is more conducive to the threading operation of the stator lead. By setting an adjustment protrusion, an adjustment bracket and a limit block, the distance after the stator lead passes through the second threading hole can be limited, thereby improving the welding effect between the stator lead and the buckle. At the same time, the moving half buckle and the fixed half buckle clamp the stator lead by rising the limit block. Under the joint action of the second buckle, the stator lead can be better fixed, thereby ensuring the stability of the connection between the stator lead and the bus bar. By providing a fixing frame, a correction frame, a plurality of extrusion strips and an extrusion frame, the stator lead can be initially fixed in the process of passing through the threading hole 1, thereby reducing the loosening of the connection between the stator lead and the buckle 1 due to the influence of external tension, and increasing the stability of the connection between the stator lead and the bus bar. At the same time, during the movement of the moving half buckle, the movement of the extrusion strip can be indirectly limited by pulling the limiting block with a pull wire, thereby improving the limiting and fixing effect of the stator lead, and can also indirectly ensure the stability of the connection between the stator lead and the bus bar. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 is a schematic diagram of the structure of the busbar in the present invention; Figure 3 It is a schematic diagram of the structure of the fixed half buckle and the movable half buckle in the present invention; Figure 4 Another structural schematic diagram of the fixed half buckle and the movable half buckle in the present invention; Figure 5 It is a cross-sectional structural schematic diagram of the fixing frame in the present invention; Figure 6 It is a schematic diagram of the structure of the gear transmission assembly in the present invention; Figure 7 Another structural schematic diagram of the buckle of the present invention is shown in FIG.

[0018] Figure markings: 1. bus bar; 2. bus bar insulating shell; 3. injection molded shell boss; 4. buckle one; 401. fixed half buckle; 402. movable half buckle; 5. adjustment assembly; 501. adjustment protrusion; 502. adjustment bracket; 6. buckle two; 601. sub-buckle; 602. female buckle; 7. limit block; 8. fixed frame; 9. correction frame; 10. extrusion strip; 11. threaded rod; 12. extrusion frame; 13. gear transmission assembly; 1301. gear one; 1302. gear two; 1303. gear three; 14. knob; 15. limit block; 16. pull wire; 17. threading hole one; 18. threading hole two. DETAILED DESCRIPTION

[0019] Embodiment 1 like Figure 1-Figure 7 As shown, an injection-molded integrated busbar proposed in the present invention comprises: three busbars 1, a busbar insulating shell 2, an injection-molded shell boss 3 and a buckle 4.

[0020] The busbar insulating shell 2 is arranged on three busbars 1, and the busbar 1 is made of stainless steel copper-plated and tin-plated material. The busbar insulating shell 2 is made of injection molding in an integrated manner. The busbar insulating shell 2 is in close contact with the busbar 1. The injection molding shell boss 3 is arranged on the busbar insulating shell 2, and a threading hole 17 is provided on the injection molding shell boss 3. A buckle 4 is arranged on the busbar 1, and the buckle 4 extends to the outside of the busbar insulating shell 2. A threading hole 2 18 is provided on the buckle 4. The buckle 4 is located directly above the injection molding shell boss 3. The threading hole 17 and the threading hole 2 18 are coaxially arranged. The buckle 4 is in an integrated manner, and a wire entry groove is provided on one side of the buckle 4, and the wire entry groove is connected to the threading hole 2 18 on the buckle 4.

[0021] The stator lead head is passed through the threading hole 17 on the injection molded shell boss 3, and then through the threading hole 2 18 on the buckle 4 and exceeds the distance of 1-2mm, and then the electric welding operation is performed on the buckle 4 to connect the stator lead and the buckle 4. The number of buckles 14 on the busbar 1 is set to four, and the number of injection molded shell bosses 3 on the busbar insulation shell 2 is set to twelve. The twelve injection molded shell bosses 3 are three adjacent to each other as a group, and are divided into four groups in total. The three injection molded shell bosses 3 in each group are in the order of the lowest, the middle height, and the highest. The heights of the busbars 1 are arranged from low to high, so that the distances between the injection molding shell boss 3 and the buckle 4 on the busbar 1 will not differ too much or too little, and the buckle 4 and the stator lead are more stable during welding. There is a certain height distance between the three busbars 1. During the injection molding of the busbar insulating shell 2, the busbar insulating shell 2 will form a barrier between the three busbars. After the injection molding, there will be no contact between the three busbars 1, thereby reducing leakage and short circuit when the busbar is in use.

[0022] In this embodiment, the busbar insulating shell 2 is formed by integral injection molding outside the three busbars 1. During installation, the busbar insulating shell 2 can be installed above the stator, so that the stator lead passes through the threading hole 17 on the injection molding shell boss 3 and then passes through the threading hole 2 18 on the buckle 1 4 and extends to 1-2 mm above the threading hole 2 18, and then the stator lead is connected to the buckle 1 4 by welding.

[0023] Embodiment 2 like Figure 1-Figure 6 As shown, the present invention proposes an injection-molded integrated busbar. Compared with the first embodiment, the buckle 1 4 is in a split structure. The buckle 1 4 is composed of a fixed half buckle 401 and a movable half buckle 402. The fixed half buckle 401 is fixedly connected to the busbar 1, and the movable half buckle 402 is arranged on one side of the fixed half buckle 401. In this embodiment, the threading hole 18 is also divided into two arc grooves, which are respectively arranged on the outer wall of the movable half buckle 402 and the fixed half buckle 401 on one side close to each other. The two arc grooves are combined to form the threading hole 18, and the tops of the two arc grooves are both set to be bucket-shaped, which can facilitate welding. The movable half buckle 402 and the fixed half buckle 401 are provided with an adjustment component 5 for adjusting the distance between the movable half buckle 402 and the fixed half buckle 401, and the movable half buckle 402 and the fixed half buckle 401 are provided with a buckle 2 6 for tightening the connection between the movable half buckle 402 and the fixed half buckle 401.

[0024] The adjusting assembly 5 is composed of two adjusting protrusions 501, two adjusting brackets 502 and a limit block 7. The two adjusting protrusions 501 are respectively mounted on the movable half buckle 402 and the fixed half buckle 401. The two adjusting brackets 502 are respectively rotatably arranged on the two adjusting protrusions 501. A rotating groove 1 is provided on the adjusting protrusion 501. A spherical groove is provided on the adjusting protrusion 501. The spherical groove is communicated with the rotating groove. The adjusting bracket 502 is composed of a spherical block and a rotating bar. The spherical block is arranged in the spherical groove and is rollingly connected to the inner wall of the spherical groove. The rotating bar is located in the rotating groove 1, and the rotating bar is movably connected to the rotating groove 1. The limit block 7 is arranged above the movable half buckle 402 and the fixed half buckle 401. The two adjusting brackets 502 are both rotatably connected to the limit block 7. When the movable half buckle 402 and the fixed half buckle 401 are in contact, the limit block 7 is located directly above the threading hole 2 18.

[0025] Buckle 2 6 is composed of a sub-buckle 601 and a mother buckle 602. The sub-buckle 601 is installed on the fixed half buckle 401, and the mother buckle 602 is installed on the movable half buckle 402. When the movable half buckle 402 and the fixed half buckle 401 contact each other, the sub-buckle 601 and the mother buckle 602 are in a clamped state. When the sub-buckle 601 and the mother buckle 602 are not clamped, two sliding grooves are provided on the sub-buckle 601, and two sliders are installed on the mother buckle 602. The two sliders are slidably connected to the two sliding grooves respectively. Through the setting of the sliding grooves and the sliders, the relative stability of the movable half buckle 402 and the fixed half buckle 401 can be improved.

[0026] The threading holes 17 on the three injection-molded shell bosses 3 of the same group are arranged in sequence as perforations, countersunk holes, and countersunk holes. A fixing frame 8 is arranged in the threading hole 17. The top and bottom of the fixing frame 8 are both set as openings. A correction frame 9 is arranged in the fixing frame 8. The upper end of the correction frame 9 is set as a circular hole shape, and the lower end is set as a cone shape, which is used to correct the stator lead wire, so as to facilitate guiding the stator lead wire head to pass through the threading hole 17 to reach the buckle 4. A plurality of extrusion strips 10 are installed on the correction frame 9. The extrusion strips 10 are made of plastic material. The extrusion strips 10 are made of a structure that is wide at the top and narrow at the bottom. An extrusion frame 12 is sleeved on the plurality of extrusion strips 10. The fixing frame 8 is set There is a lifting mechanism for lifting the extrusion frame 12, the lifting mechanism includes a threaded rod 11 rotatably mounted on the fixed frame 8, a gear transmission assembly 13 is arranged on the fixed frame 8, the gear transmission assembly 13 is composed of gear one 1301, gear two 1302 and gear three 1303, gear one 1301, gear two 1302 and gear three 1303 are meshed and connected with each other, gear one 1301 is sleeved on the threaded rod 11, a knob 14 is arranged on the fixed frame 8, one side of the knob 14 extends to the outside of the fixed frame 8 and extends to the outside of the injection molding shell boss 3, the knob 14 is connected to gear three 1303, and is used to drive gear three 1303 to rotate.

[0027] A limiting block 15 is slidably installed in the fixed frame 8, and a T-bar is installed on the top of the fixed frame 8. The T-bar passes through the limiting block 15 and is slidably connected to the limiting block 15. A long cylinder is installed on the top of the fixed frame 8, and the top of the long cylinder extends to a height of 10-15mm below the corresponding buckle 4. A pull wire 16 is arranged on the limiting block 15, and the other end of the pull wire 16 is connected to the movable half buckle 402. The pull wire 16 is connected to the movable half buckle 402 via the long cylinder, which can improve the protection of the pull wire 16. One side of the limiting block 15 is conically set, and the distance between the conical side and the two adjacent racks on the gear 1301 is the same.

[0028] In this embodiment, when in use, after the stator lead is passed through the fixed frame 8, the threading hole 17 and the threading hole 2 18, the stator lead is brought into contact with the limit block 7 and the limit block 7 is pushed up. During the rising process of the limit block 7, the two adjusting brackets 502 and the two adjusting protrusions 501 drive the movable half buckle 402 to move toward the fixed half buckle 401, so that the movable half buckle 402 and the fixed half buckle 401 clamp the stator lead. Moreover, through the setting of the limit block 7, the distance after the stator lead head passes through the threading hole 2 18 can be limited, so that the stator lead head extends to a height of 1-2mm above the threading hole 2 18, thereby ensuring the welding effect of the stator lead. When the movable half buckle 402 contacts the fixed half buckle 401, the sub-buckle 601 and the female buckle 602 form a clamping state with each other. When the female buckle 602 is not subjected to external forces, the connection stability between the movable half buckle 402 and the fixed half buckle 401 can be ensured. After the stator lead passes through the fixed frame 8 and extends to the top of the threading hole 17, the knob 14 can be turned to drive the threaded rod 11 to rotate through the gear transmission assembly 13, and then drive the extrusion frame 12 to rise, and then push the multiple extrusion bars 10 to move toward the stator lead, squeeze the stator lead, and increase the limit fixation of the stator lead. When the stator lead pushes the limit block 7 to rise and drives the moving half buckle 402 to move, it will pull the pull wire 16 to drive the lower limit block 15 to rise, and limit the gear 1301, thereby limiting the rotation of the threaded rod 11, ensuring the stability of the extrusion frame 12, thereby ensuring the stability of the limit of the stator lead, and preventing the stator lead from being affected by the vibration of the motor, thereby affecting the stability of the connection between the stator lead and the buckle.

[0029] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited thereto, and various changes can be made within the knowledge scope of technicians in the relevant technical field without departing from the purpose of the present invention.

Claims

1. An injection molded integrated busbar, comprising: The busbar (1) is characterized in that A busbar insulation shell (2) is arranged on the busbar (1), the busbar insulation shell (2) is formed by injection molding, the busbar insulation shell (2) is in close contact with the busbar (1), an injection molding shell boss (3) is arranged on the busbar insulation shell (2), a threading hole (17) is provided on the injection molding shell boss (3), a buckle (4) is arranged on the busbar (1), the buckle (4) extends to the outside of the busbar insulation shell (2), a threading hole (18) is provided on the buckle (4), the buckle (4) is located directly above the injection molding shell boss (3), and the threading hole (17) and the threading hole (18) are arranged coaxially; Pass the stator lead through the first threading hole (17) on the injection molded shell boss (3), and then through the second threading hole (18) on the first buckle (4), and then connect the stator lead and the first buckle (4) by welding; The corresponding three injection-molded shell bosses (3) are arranged in order from the lowest to the middle height and the highest, and the heights of the busbars (1) are also arranged in order from the lowest to the highest. The threading holes (17) on the injection-molded shell bosses (3) are used to maintain the stability of the buckle (4) and the stator lead when being welded; There is a certain height distance between the bus bars (1). During the injection molding process of the bus bar insulation shell (2), the bus bar insulation shell (2) will form a barrier between the bus bars (1), and after the injection molding, the bus bars (1) will not come into contact with each other.

2. The injection-molded integrated busbar according to claim 1, characterized in that: The buckle 1 (4) is integrally formed, and a wire entry slot is provided on one side of the buckle 1 (4), the wire entry slot being connected to the wire threading hole 2 (18) on the buckle 1 (4).

3. The injection-molded integrated busbar according to claim 1, characterized in that: The first buckle (4) is of split construction, and is composed of a fixed half buckle (401) and a movable half buckle (402). The fixed half buckle (401) is fixedly connected to the bus bar (1), and the movable half buckle (402) is arranged on one side of the fixed half buckle (401). The movable half buckle (402) and the fixed half buckle (401) are provided with an adjustment component (5) for adjusting the distance between the movable half buckle (402) and the fixed half buckle (401). The movable half buckle (402) and the fixed half buckle (401) are provided with a second buckle (6) for tightening the connection between the movable half buckle (402) and the fixed half buckle (401).

4. The injection-molded integrated busbar according to claim 3, characterized in that: The adjustment assembly (5) is composed of two adjustment protrusions (501), two adjustment brackets (502) and a limit block (7); the two adjustment protrusions (501) are respectively mounted on the movable half buckle (402) and the fixed half buckle (401); the two adjustment brackets (502) are respectively rotatably mounted on the two adjustment protrusions (501); the limit block (7) is disposed above the movable half buckle (402) and the fixed half buckle (401); and the two adjustment brackets (502) are both rotatably connected to the limit block (7).

5. The injection-molded integrated busbar according to claim 3, characterized in that: Buckle 2 (6) is composed of a sub-buckle (601) and a female buckle (602), wherein the sub-buckle (601) is mounted on the fixed half buckle (401), and the female buckle (602) is mounted on the movable half buckle (402). When the movable half buckle (402) and the fixed half buckle (401) are in contact with each other, the sub-buckle (601) and the female buckle (602) are in a locked state.

6. The injection-molded integrated busbar according to claim 3, characterized in that: The threading holes (17) on the three injection-molded shell bosses (3) of the same group are arranged in the form of a through hole, a countersunk hole, and a countersunk hole in sequence. A fixing frame (8) is arranged inside the threading hole (17). A correction frame (9) is arranged inside the fixing frame (8). A plurality of extrusion bars (10) are mounted on the correction frame (9). An extrusion frame (12) is sleeved on the plurality of extrusion bars (10). A lifting mechanism is arranged on the fixing frame (8) for lifting the extrusion frame (12).

7. The injection-molded integrated busbar according to claim 6, characterized in that: The lifting mechanism comprises a threaded rod (11) rotatably mounted on a fixed frame (8); a gear transmission assembly (13) is arranged on the fixed frame (8); the gear transmission assembly (13) is composed of a gear 1 (1301), a gear 2 (1302) and a gear 3 (1303); the gear 1 (1301), the gear 2 (1302) and the gear 3 (1303) are meshed and connected with each other; the gear 1 (1301) is sleeved on the threaded rod (11); a rotating knob (14) is arranged on the fixed frame (8); one side of the rotating knob (14) extends outside the fixed frame (8) and outside the injection molded shell boss (3); the rotating knob (14) is connected to the gear 3 (1303) and is used to drive the gear 3 (1303) to rotate.

8. The injection-molded integrated busbar according to claim 6, characterized in that: A limiting block (15) is slidably mounted in the fixed frame (8), a pull wire (16) is arranged on the limiting block (15), the other end of the pull wire (16) is connected to the movable half buckle (402), one side of the limiting block (15) is arranged in a conical shape, and the distance between the conical side and two adjacent racks on the gear one (1301) is the same.

9. The injection-molded integrated busbar according to claim 6, characterized in that: The upper end of the correction frame (9) is configured to be in the shape of a circular hole, and the lower end is configured to be in the shape of a cone, and is used to correct the stator lead wire, so as to facilitate guiding the stator lead wire head to pass through the threading hole 1 (17) to reach the buckle 1 (4).

10. The injection-molded integrated busbar according to claim 6, characterized in that: The extruded strip (10) is made of a plastic material, and has a structure that is wide at the top and narrow at the bottom.

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