High-voltage busbar

Abstract

The invention relates to the technical field of high-voltage busbars, and discloses a high-voltage busbar which comprises a core wire bar, a composite layer, a pressure-resistant layer and a wear-resistant layer are sequentially arranged on the outer side of the core wire bar, the composite layer is arranged on the outer side of the core wire bar in a plastic coating mode and used for improving insulation, high temperature resistance and flame retardance of the busbar, the pressure-resistant layer is fixed between the composite layer and the wear-resistant layer, and the wear-resistant layer is fixed between the composite layer and the wear-resistant layer. The core wire bar is used for improving the compression strength of the busbar and is one of a copper bar and an aluminum bar; the composite layer is made of a mixed material of ceramic silica gel and mica powder; the pressure-resistant layer is made of a PI material or a mica paper material; and the wear-resistant layer is made of a TPU material. According to the high-voltage busbar, the outer side of the core wire bar is coated with the composite layer, the pressure-resistant layer and the wear-resistant layer, so that the requirements of high voltage, insulation, pressure resistance, wear resistance and the like of the busbar are met, it is guaranteed that the busbar is safely used on a high-voltage line on an automobile, the use process is stable, the service life is long, the production process is easy to operate, the material cost and the process cost are low, and the production cost is low. And the actual busbar batch production requirement is met.

Description

Technical Field

[0001] The invention relates to the technical field of high-voltage busbars, in particular to a high-voltage busbar. Background Art

[0002] The application of busbars in the field of new energy vehicles is mainly used for power battery module connection and inverter connection scenarios. The busbar is composed of an inner layer of conductive material copper or aluminum and an outer layer of insulating material.

[0003] In the prior art, the name disclosed in the application number: CN202321849510.7 is: copper busbar assembly, busbar, motor and automobile, which includes a first copper busbar body, the first copper busbar body includes a main body section and a heat-conducting section connected to the main body section, the temperature measuring component includes a sheath and a temperature sensor, the sheath and the heat-conducting section are clamped and fixed to form a clamping space to clamp and fix the temperature sensor.

[0004] However, the bus mentioned in the prior art, in actual production, uses a single material to form an insulating outer layer, which is difficult to meet the performance requirements of the automotive bus. Using a combination of multiple materials and processes to meet the requirements will increase production costs. Therefore, it is necessary to design a high-voltage bus. Summary of the invention

[0005] The object of the present invention is to provide a high-voltage busbar to solve the problems in the prior art.

[0006] The purpose of the present invention can be achieved through the following technical solutions:

[0007] A high-voltage busbar, the busbar comprises a core wire row, the outer side of the core wire row is sequentially provided with a composite layer, a pressure-resistant layer and a wear-resistant layer, the composite layer is plastic-coated and arranged on the outer side of the core wire row, and is used to improve the insulation, high temperature resistance and flame retardancy of the busbar, the pressure-resistant layer is fixed between the composite layer and the wear-resistant layer, and is used to improve the pressure resistance of the busbar, and the outer side of the pressure-resistant layer is wrapped with a wear-resistant layer with elasticity and high wear resistance, and is used to improve the wear times of the high-voltage busbar.

[0008] Furthermore, the core wire row is one of a copper row and an aluminum row.

[0009] Furthermore, the composite layer is made of a mixed material of ceramic silica gel and mica powder.

[0010] Furthermore, the pressure-resistant layer is made of PI material or mica paper material.

[0011] Furthermore, the wear-resistant layer is made of TPU material.

[0012] Furthermore, the core wire array is provided with through grooves for separating the core wire rows, and the outer side of the wear-resistant layer is provided with a plurality of grooves for bending the busbar.

[0013] Furthermore, two parallel core wire rows are provided in the composite layer, and a cushion layer is fixedly provided between the two core wire rows to separate the two core wire rows.

[0014] Furthermore, the cushion layer adopts two insulating layers, a flame retardant layer and a reinforcement layer are fixedly arranged between the two insulating layers, one side of the flame retardant layer is connected to the reinforcement layer, and the other side is connected to the insulating layer.

[0015] Furthermore, the insulating layer is made of ceramic silicone material with a thickness of 0.2-0.4 mm, the flame retardant layer is made of PI material or mica paper material with a thickness of 0.05-0.20 mm, and the reinforcement layer is made of TPU material with a thickness of 0.3-0.6 mm.

[0016] Beneficial effects of the present invention:

[0017] 1. The high-voltage busbar of the present invention adopts a composite layer, a pressure-resistant layer and a wear-resistant layer coated on the outer side of the core wire row to meet the requirements of high voltage, insulation, pressure resistance and wear resistance of the busbar, and ensure the safe use of the high-voltage line of the busbar on the car, and the use process is stable and the service life is long;

[0018] 2. The high-voltage busbar of the present invention has a simple structure, a simple production process, and simple material acquisition, so that the material cost and process cost are relatively low, meeting the actual busbar mass production needs and the actual use needs of the busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be further described below in conjunction with the accompanying drawings.

[0020] Figure 1 It is a schematic diagram of the busbar structure of the present invention;

[0021] Figure 2 It is a schematic diagram of the structure of the busbar of the present invention;

[0022] Figure 3 is a schematic cross-sectional structural diagram of the busbar of the present invention;

[0023] Figure 4 It is a schematic diagram of the internal structure of the busbar of the present invention;

[0024] Figure 5 It is a schematic diagram of the cushion structure of the present invention. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] Embodiment 1:

[0027] A high-voltage busbar, mainly used in high-voltage environments, such as Figure 1 As shown, the busbar includes a core wire row 1, which is made of conductive material, mainly one of copper and aluminum. A composite layer 2, a pressure-resistant layer 3 and a wear-resistant layer 4 are sequentially arranged on the outside of the core wire row 1. The composite layer 2 is plastic-coated on the outside of the core wire row 1, and the pressure-resistant layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0028] In this embodiment, the composite layer 2 is made of a mixture of ceramic silicone and mica powder, and is mainly formed by extrusion processing technology and coated on the outside of the core wire row 1. The ceramic silicone and mica powder materials have ultra-high insulation performance and high temperature resistance. They are inorganic insulating materials that can withstand temperatures above 800°C and have high compressive strength and are not easy to break down, so that the insulation withstand voltage of the prepared bus after high-temperature baking is not less than 3000V.

[0029] In this embodiment, the pressure-resistant layer 3 is made of PI material or mica paper material. The polyimide film or mica paper is mainly wrapped and packaged on the composite layer 2 through a winding process. At least one layer is wrapped to form a pressure-resistant protective structure on the outside of the composite layer 2, which serves to protect the inner layer of ceramic silicone material and improve the insulation withstand voltage.

[0030] In this embodiment, the wear-resistant layer 4 is made of TPU material, and the thermoplastic polyurethane elastomer is mainly formed on the outside of the pressure-resistant layer 3 by extrusion processing. It is elastic and has ultra-high wear resistance, and the number of wear resistance is more than twice that of the existing line row.

[0031] Beneficial effect: The outer side of the core wire row 1 is provided with a composite layer 2 made of ceramic silica gel and mica powder, a pressure-resistant layer 3 made of PI material or mica paper material, and a wear-resistant layer 4 made of TPU in sequence. The composite layer 2 is used to improve the insulation performance, high temperature resistance and flame retardancy of the busbar to meet the use in high temperature and high pressure environments.

[0032] The pressure-resistant layer 3 protects the inner ceramic silicone material and improves the insulation pressure resistance. The wear-resistant layer 4 is elastic and super wear-resistant. The first layer of plastic coating material has low cost and can be continuously produced by extrusion technology, which can save 40% of material and production costs.

[0033] Embodiment 2:

[0034] A high-voltage busbar, mainly used in high-voltage environments, such as Figure 1 As shown, the busbar includes a core wire row 1, which is made of conductive material, mainly one of copper and aluminum. A composite layer 2, a pressure-resistant layer 3 and a wear-resistant layer 4 are sequentially arranged on the outside of the core wire row 1. The composite layer 2 is plastic-coated on the outside of the core wire row 1, and the pressure-resistant layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0035] In this embodiment, the composite layer 2 is made of a mixture of ceramic silicone and mica powder, and is mainly formed by extrusion processing technology and coated on the outside of the core wire row 1. The ceramic silicone and mica powder materials have ultra-high insulation performance and high temperature resistance. They are inorganic insulating materials that can withstand temperatures above 800°C and have high compressive strength and are not easy to break down, so that the insulation withstand voltage of the prepared bus after high-temperature baking is not less than 3000V.

[0036] In this embodiment, the pressure-resistant layer 3 is made of PI material or mica paper material. The polyimide film or mica paper is mainly wrapped and packaged on the composite layer 2 through a winding process. At least one layer is wrapped to form a pressure-resistant protective structure on the outside of the composite layer 2, which serves to protect the inner layer of ceramic silicone material and improve the insulation withstand voltage.

[0037] In this embodiment, the wear-resistant layer 4 is made of TPU material, and the thermoplastic polyurethane elastomer is mainly formed on the outside of the pressure-resistant layer 3 by extrusion processing. It is elastic and has ultra-high wear resistance, and the number of wear resistance is more than twice that of the existing line row.

[0038] like Figure 2 , Figure 3 As shown, the core wire row 1 is provided with array-distributed through slots 11. After the busbar is cut off at the through slots 11, the outer wrapping structure is peeled off, and the core wire row 1 can be divided into two wiring terminals at the through slots 11, which is convenient for actual wiring use.

[0039] A plurality of grooves 41 are provided on the outside of the wear-resistant layer 4. The grooves 41 are arranged in a ring shape on the outside of the wear-resistant layer 4 to facilitate the bending of the core wire row 1. At the same time, grooves 41 are provided at both ends of the through groove 11 so that the position of the through groove 11 can be identified and confirmed during actual use.

[0040] In actual use, when the bus needs to be wired separately, it is cut at the two grooves 41 as needed, and the core wire row 1 of the bus is bent at the through groove 11, and the wires are used separately without additional cutting operations. At the same time, bending at the groove 41 can reduce the wrinkles produced on the wear-resistant layer 4 after bending, and save effort in the bending and wiring operations of the bus.

[0041] Embodiment 3:

[0042] A high-voltage busbar, mainly used in high-voltage environments, such as Figure 1As shown, the busbar includes a core wire row 1, which is made of conductive material, mainly one of copper and aluminum. A composite layer 2, a pressure-resistant layer 3 and a wear-resistant layer 4 are sequentially arranged on the outside of the core wire row 1. The composite layer 2 is plastic-coated on the outside of the core wire row 1, and the pressure-resistant layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0043] In this embodiment, the composite layer 2 is made of a mixture of ceramic silicone and mica powder, and is mainly formed by extrusion processing technology and coated on the outside of the core wire row 1. The ceramic silicone and mica powder materials have ultra-high insulation performance and high temperature resistance. They are inorganic insulating materials that can withstand temperatures above 800°C and have high compressive strength and are not easy to break down, so that the insulation withstand voltage of the prepared bus after high-temperature baking is not less than 3000V.

[0044] In this embodiment, the pressure-resistant layer 3 is made of PI material or mica paper material. The polyimide film is wrapped and packaged on the composite layer 2 mainly through winding processing, and at least one layer is wrapped to form a pressure-resistant protection structure on the outside of the composite layer 2, which plays a role in protecting the inner layer of ceramic silicone material and improving the insulation withstand voltage.

[0045] In this embodiment, the wear-resistant layer 4 is made of TPU material, and the thermoplastic polyurethane elastomer is mainly formed on the outside of the pressure-resistant layer 3 by extrusion processing. It is elastic and has ultra-high wear resistance, and the number of wear resistance is more than twice that of the existing line row.

[0046] like Figure 4 As shown, two parallel core wire rows 1 are arranged in the composite layer 2 to achieve transmission of at least one core wire row 1 , and a cushion layer 5 is fixedly arranged between the two core wire rows 1 , and the cushion layer 5 is used to separate the two core wire rows 1 .

[0047] The cushion layer 5 comprises two insulating layers 51 , between which a flame retardant layer 52 and a reinforcing layer 53 are fixedly arranged, and one side of the flame retardant layer 52 is bonded to the reinforcing layer 53 , and the other side of the flame retardant layer 52 is bonded to the insulating layer 51 .

[0048] The insulating layer 51 is made of ceramic silicone material, has insulating properties, and has a thickness of 0.2-0.4mm. The flame retardant layer 52 is made of PI material or mica paper material, has a flame retardant effect and an insulating effect, and has a thickness of 0.05-0.20mm. The reinforcing layer 53 is made of TPU material, has insulating and tensile effects, and has a thickness of 0.3-0.6mm.

[0049] A cushion layer 5 is provided between the two core wire rows 1 to separate and insulate the two core wire rows 1, thereby ensuring that the two core wire rows 1 work independently and stably without interfering with each other, thereby increasing the working life of the busbar in a high current and high voltage environment.

[0050] Under the condition of the conventional use temperature range of -40°C to 125°C, two comparative examples are added for comparison with the busbar of the present invention, as follows:

[0051] Comparative Example 1: A conductor + insulation layer design is adopted, and the insulation layer is usually PA11 / PA12;

[0052] Comparative Example 1 usually lacks high-temperature insulation performance testing. Disadvantages: There is no high-temperature resistant flame-retardant material, and it cannot meet the insulation performance requirements of the power battery after thermal runaway. It is necessary to add additional high-temperature resistant flame-retardant materials on the application side to compensate.

[0053] Comparative Example 2: A design of conductor + mica layer + insulating layer is adopted, and the insulating layer is usually PA11 / PA12.

[0054] Comparative Example 2 meets the 400°C short-term high-temperature insulation performance (1H test);

[0055] Test requirements: After baking at 400℃, the leakage current is less than 10mA, and the maximum withstand voltage value is confirmed;

[0056] Actual test: Maximum withstand voltage 2KV~2.5KV.

[0057] The high-voltage busbar of the present invention meets the short-term high-temperature insulation performance of 400°C (1H test);

[0058] Test requirements: After baking at 400℃, the leakage current is less than 10mA, and the maximum withstand voltage value is confirmed;

[0059] Actual test: Maximum withstand voltage 3KV~3.5KV.

[0060] The advantages of the high-voltage busbar of the present invention are: meeting the requirements of high-temperature insulation and flame retardancy, and the ceramic silicone layer improves the high-temperature insulation performance; the ceramic silicone layer is extruded in one piece, with low material cost, high material utilization rate, and an environmentally friendly material production process.

[0061] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A high-voltage busbar, comprising a core line bar (1), characterized in that: The outer side of the core wire row (1) is provided with a composite layer (2), a pressure-resistant layer (3) and a wear-resistant layer (4) in sequence; the composite layer (2) is plastic-coated and arranged on the outer side of the core wire row (1) to improve the insulation, high temperature resistance and flame retardancy of the busbar; the pressure-resistant layer (3) is fixed between the composite layer (2) and the wear-resistant layer (4) to improve the pressure resistance of the busbar; the outer side of the pressure-resistant layer (3) is wrapped with a wear-resistant layer (4) having elasticity and high wear resistance to improve the wear resistance of the high-voltage busbar.

2. A high-voltage busbar according to claim 1, characterized in that: The core wire row (1) is a copper row or an aluminum row.

3. A high-voltage busbar according to claim 1, characterized in that: The composite layer (2) is made of a mixed material of ceramic silica gel and mica powder.

4. A high-voltage busbar according to claim 1, characterized in that: The pressure-resistant layer (3) is made of PI material or mica paper material.

5. A high-voltage busbar according to claim 1, characterized in that: The wear-resistant layer (4) is made of TPU material.

6. A high-voltage busbar according to claim 1, characterized in that: The core wire row (1) is provided with through grooves (11) in an array for separating the core wire rows (1), and the outer side of the wear-resistant layer (4) is provided with a plurality of grooves (41) for bending the busbar.

7. A high-voltage busbar according to claim 1, characterized in that: Two parallel core wire rows (1) are arranged in the composite layer (2), and a cushion layer (5) is fixedly arranged between the two core wire rows (1) to separate the two core wire rows (1).

8. A high-voltage busbar according to claim 7, characterized in that: The cushion layer (5) comprises two insulating layers (51), a flame retardant layer (52) and a reinforcing layer (53) are fixedly arranged between the two insulating layers (51), one side of the flame retardant layer (52) is connected to the reinforcing layer (53), and the other side is connected to the insulating layer (51).

9. A high-voltage busbar according to claim 8, characterized in that: The insulating layer (51) is made of ceramic silicone material with a thickness of 0.2-0.4 mm, the flame retardant layer (52) is made of PI material or mica paper material with a thickness of 0.05-0.20 mm, and the reinforcing layer (53) is made of TPU material with a thickness of 0.3-0.6 mm.

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