Insulation powder dipping process for busbar
Through a process including stamping, cleaning, sandblasting, preheating, powder impregnation and curing treatment, the problem that the busbar insulation treatment process cannot achieve assembly line production is solved, and the busbar insulation performance with good insulation thickness consistency and high pressure resistance is achieved. It is suitable for fast flowing automatic production lines.
Patent Information
- Application Number
- CN202411845878.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-16
- Publication Date
- 2025-03-21
AI Technical Summary
The existing busbar insulation treatment process cannot achieve assembly line production, poor consistency of insulation thickness, resulting in unstable pressure resistance, uneven interface between the connector and the insulating part, the protective sleeve is easy to bond and not easily remove, and the adhesiveness between the insulating powder and the substrate is poor, and it is easy to fall off.
An insulating impregnation powder process including stamping, cleaning, drying, shielding treatment, sandblasting, preheating, impregnation and curing treatment is adopted. The process ensures that the busbar surface is clean through alkaline washing, pickling and ultrasonic cleaning, sandblasting treatment increases adhesion of insulating powders, the use of aluminum foil sleeves and fiberglass tapes simplifies shielding, and robotic clamps and heating molds are used to control the impregnation and curing process.
It has achieved good consistency in the insulation thickness of the busbar, high pressure resistance, and excellent insulation performance. It is suitable for fast flow automatic production lines, and has controllable pressure resistance. The impregnation process is optimized, the adhesion and consistency between the insulating powder and the substrate are improved, and the service life of the product is extended.
Smart Images
Figure CN119673588A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of busbar insulation, and in particular relates to an insulation powder dipping process for a busbar. Background Art
[0002] Powder coating is a technology commonly used for metal surface coating. It forms a uniform and durable coating by dipping powdered coating into the molten substrate surface. This process can provide metal products with functions such as corrosion resistance, oxidation resistance, wear resistance, and aesthetics, so it is widely used in the automotive, furniture, electronics, construction and other industries. As a common and commonly used conductive device, the conductive busbar is widely used in the electronic processing industry, the automotive industry, the energy storage field, etc., to transmit signals and connect circuits. Compared with general terminal-type conductive devices, the conductive busbar itself is mainly made of larger metal plates. The two ends serve as circuit connection ends, and the middle part needs to be insulated for safety. The existing busbar insulation treatment process cannot form an assembly line production. The surface insulation thickness consistency of the product after powder dipping is poor, resulting in unstable withstand voltage value. The interface between the connector and the insulating part is uneven after plastic dipping, the protective cover is easy to stick and difficult to remove, and the insulation powder has poor adhesion to the substrate and is easy to fall off.
[0003] Therefore, it is necessary to develop an insulation powder dipping process for busbars to solve the above technical problems. Summary of the invention
[0004] Purpose of the invention: The purpose of the present invention is to provide an insulation powder dipping process for busbars to solve the above-mentioned technical problems.
[0005] Technical solution: In order to achieve the above-mentioned purpose, the present invention provides an insulation powder dipping process for busbars, comprising the following steps: S1, stamping: stamping the metal blank into shape; S2, cleaning: cleaning the stamped busbar, firstly alkali cleaning and then rinsing with clean water, then cleaning with acid solution, and finally putting it into clean water for ultrasonic cleaning; S3, Drying: After the busbar is cleaned, use an air gun to blow away the water stains on the product and put it in the oven to dry; S4, shielding treatment: Cover the connectors at both ends of the busbar with protective bags and seal the protective bags with tape; S5, sandblasting: the busbar is suspended on the conveyor line and sent to the sandblasting equipment for sandblasting; S6, preheating: preheating the busbar after sandblasting, and placing the busbar into a heating mold, the temperature of the heating mold is 195-225℃; S7, powder dipping: Use a robot to pick up the preheated busbar and immerse it in epoxy resin powder. The immersion time is 1.8S / PCS. After the powder dipping is completed, tear off the sealing tape and protective cover; S8, curing treatment: hang the busbars that have been dipped in powder on the hooks on the conveyor line and send them into the large oven for curing treatment.
[0006] Furthermore, the specific method of cleaning in step S1 is: put the busbar into a dedicated cleaning frame, then put the cleaning frame into an alkaline cleaning tank, put it into an alkaline cleaning tank with an alkaline solution replaced for a second alkaline cleaning after the first alkaline cleaning is completed, put it into a clean water tank for cleaning after the alkaline cleaning is completed, and then put it into an acid cleaning tank for acid cleaning, and finally put it into clean water for ultrasonic cleaning. First, put the busbar into the alkaline cleaning tank for cleaning to remove oil, dirt, etc. on its surface. To ensure the cleaning effect, a second alkaline cleaning is performed. After the alkaline cleaning is completed, clean water is used to clean the surface impurities and the alkaline solution remaining on the surface; then put it into the acid cleaning tank for cleaning. The role of acid cleaning is to remove the oxides on the surface of the busbar and neutralize the residual alkaline solution to ensure that the insulating powder can be firmly attached to the surface of the busbar. Finally, ultrasonic cleaning is used to ensure that there are no impurities on the surface of the busbar.
[0007] Furthermore, the pH value of the solution in the alkaline washing tank is 9-11, the pH value of the solution in the acid washing tank is 2-4, the temperature of the solution in the alkaline washing tank is 65-75° C., and the cleaning time for each cleaning is 5-10 minutes.
[0008] Furthermore, the oven baking temperature in step S3 is 105-125° C., and the baking time is 20-30 minutes. During the drying process, the moisture on the busbar surface must be dried, and the baking temperature must be strictly controlled to avoid excessively high temperature and the formation of an oxide layer on the busbar surface.
[0009] Furthermore, the protective cover in step S4 is an aluminum foil cover, and the adhesive tape is a glass fiber tape. The protective cover is removed immediately after the powder is dipped. When removing the protective cover, it is only necessary to tear off the adhesive tape to remove the protective cover. The adhesive tape will not be difficult to tear off due to adhesion with the insulating powder. It is efficient and quick, and after removing the protective cover, the interface between the insulating part and the connector part is flat.
[0010] Furthermore, the specific method of sandblasting in step S5 is: the busbars are sequentially placed on a conveyor belt and sent into a sandblasting machine, and after one round of sandblasting, the busbars are turned over for a second round of sandblasting, and the busbars after sandblasting are dusted with an air gun. The busbars are sandblasted to make the surface of the insulating part rough, thereby improving the adhesion with the insulating powder and making the bonding more reliable.
[0011] Furthermore, the conveying frequency of the conveyor belt is 25-35 mm / s, the swing frequency of the sandblasting gun is 40-50 Hz, and the flow rate of the sandblasting gun is 0.5-1 m 3 / min, the sandblasting particles are 80 mesh brown corundum sand.
[0012] Furthermore, after the busbar is dipped in powder, the powder thickness is within 0.34-0.37 mm.
[0013] Furthermore, after the powder dipping is completed, it also includes checking whether there are impurities on the surface of the mother bar powder and screening the powder in time.
[0014] Furthermore, in step S8, the temperature of the large oven is 170-190°C, the speed of the large oven is 22Hz, and the heating and curing time of a single product is at least 20 minutes. The busbar after powder dipping is cured, and the insulating powder on the surface of the busbar is cured and the hardness is solidified, and the adhesion can be further improved.
[0015] It can be seen from the above technical solution that the present invention has the following beneficial effects: 1. The present invention provides an insulation powder dipping process for busbars, which can be applied to fast flow automatic production lines. The busbars manufactured by the process have good insulation thickness consistency, high withstand voltage value and good insulation performance, and can be applied in high-voltage conductive dense spaces. The withstand voltage value can be controlled by adjusting the preheating temperature and the powder dipping time.
[0016] 2. The present invention optimizes the powder dipping process. During the shielding process, an aluminum foil sleeve is used to cover the part of the busbar that does not need to be insulated. Compared with the traditional method of wrapping tape, it is more convenient and quicker. Deshielding is performed immediately after powder dipping. At this time, it is relatively easy to remove the tape and the aluminum foil sleeve. Removal will not affect the insulating powder surface, the smoothness of the interface between the insulating part and the connector part, and avoid the tape from easily adhering to the insulating powder surface during deshielding after curing, which makes it difficult to remove or damages the insulating powder surface, affecting product quality.
[0017] 3. The busbar made by the powder dipping process provided by the present invention has better adhesion and high consistency between the base material and the insulating powder, and has significantly improved insulation performance and service life. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 The present invention is a flow chart of an insulation powder dipping process for a busbar. DETAILED DESCRIPTION
[0019] It should be understood that the specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention.
[0020] like Figure 1 As shown, a process for insulating a busbar with powder dipping includes the following steps: S1, stamping: stamping the metal blank into shape; S2, cleaning: cleaning the stamped busbar, firstly alkali cleaning and then rinsing with clean water, then cleaning with acid solution, and finally putting it into clean water for ultrasonic cleaning; S3, Drying: After the busbar is cleaned, use an air gun to blow away the water stains on the product and put it in the oven to dry; S4, shielding treatment: Cover the connectors at both ends of the busbar with protective bags and seal the protective bags with tape; S5, sandblasting: the busbar is suspended on the conveyor line and sent to the sandblasting equipment for sandblasting; S6, preheating: preheating the busbar after sandblasting, and placing the busbar into a heating mold, the temperature of the heating mold is 195-225℃; S7, powder dipping: Use a robot to pick up the preheated busbar and immerse it in epoxy resin powder. The immersion time is 1.8S / PCS. After the powder dipping is completed, tear off the sealing tape and protective cover; S8, curing treatment: hang the busbars that have been dipped in powder on the hooks on the conveyor line and send them into the large oven for curing treatment.
[0021] Specifically, the specific method of cleaning in step S1 is: put the busbar into a dedicated cleaning frame, then put the cleaning frame into an alkaline washing tank, after the first alkaline washing is completed, put it into the alkaline washing tank with the alkaline solution replaced for a second alkaline washing, after the alkaline washing is completed, put it into a clean water tank for cleaning, then put it into an acid washing tank for acid washing, and finally put it into clean water for ultrasonic cleaning. The busbar in this embodiment is made of copper busbar. It should be noted that the cleaning method varies depending on the material of the busbar. For example, copper busbars are mainly acid washed, while travel busbars are mainly alkaline washed and cannot be acid washed.
[0022] The pH value of the solution in the alkaline washing tank is 9-11, the pH value of the solution in the acid washing tank is 2-4, the temperature of the solution in the alkaline washing tank is 65-75° C., and the cleaning time for each cleaning is 5-10 minutes.
[0023] Specifically, the oven baking temperature in step S3 is 105-125° C., and the baking time is 20-30 minutes.
[0024] In this embodiment, the protective cover in step S4 is an aluminum foil cover, and the adhesive tape is a glass fiber tape. The aluminum foil cover can be easily and quickly covered on the connector parts at both ends of the busbar, which greatly improves the efficiency of traditional tape wrapping and is more convenient to remove.
[0025] Specifically, the specific method of sandblasting in step S5 is: placing the busbars on the conveyor belt in sequence and sending them into the sandblasting machine, turning the busbars over for a second sandblasting after one sandblasting, and removing dust from the busbars after sandblasting with an air gun.
[0026] The conveying frequency of the conveyor belt is 25-35 mm / S, the swing frequency of the sandblasting gun is 40-50 Hz, and the flow rate of the sandblasting gun is 0.5-1 m 3 / min, the sandblasting particles are 80 mesh brown corundum sand.
[0027] Specifically, the powder thickness of the busbar after powder dipping is within 0.34-0.37 mm. The powder thickness is directly related to the pressure resistance value of the product. By using this process, different powder thicknesses can be obtained by changing the powder dipping time and preheating temperature to meet various production requirements.
[0028] In addition, after the powder dipping is completed, it also includes checking whether there are impurities on the surface of the mother bar powder and screening the powder in time.
[0029] Specifically, in step S8, the temperature of the large oven is 170-190° C., the speed of the large oven is 22 Hz, and the heating and curing time of a single product is at least 20 minutes.
[0030] The above description is only a preferred embodiment of the present invention. It should be pointed out that a person skilled in the art can make several improvements without departing from the principle of the present invention, and these improvements should also be regarded as within the protection scope of the present invention.
Claims
1. A process for insulating busbars by powder dipping, characterized in that: The steps include: S1, stamping: stamping the metal blank into shape; S2, cleaning: cleaning the stamped busbar, firstly alkali cleaning and then rinsing with clean water, then cleaning with acid solution, and finally putting it into clean water for ultrasonic cleaning; S3, Drying: After the busbar is cleaned, use an air gun to blow away the water stains on the product and put it in the oven to dry; S4, shielding treatment: Cover the connectors at both ends of the busbar with protective bags and seal the protective bags with tape; S5, sandblasting: the busbar is suspended on the conveyor line and sent to the sandblasting equipment for sandblasting; S6, preheating: preheating the busbar after sandblasting, and placing the busbar into a heating mold, the temperature of the heating mold is 195-225℃; S7, powder dipping: Use a robot to pick up the preheated busbar and immerse it in epoxy resin powder. The immersion time is 1.8S / PCS. After the powder dipping is completed, tear off the sealing tape and protective cover; S8, curing treatment: hang the busbars that have been dipped in powder on the hooks on the conveyor line and send them into the large oven for curing treatment.
2. The insulation powder dipping process for busbar according to claim 1 is characterized in that: The specific method of cleaning in step S1 is: placing the mother row into a dedicated cleaning frame, and then placing the cleaning frame into an alkaline cleaning tank. After the first alkaline cleaning is completed, it is placed in an alkaline cleaning tank with replaced alkaline solution for a second alkaline cleaning. After the alkaline cleaning is completed, it is placed in a clean water tank for cleaning, and then placed in an acid cleaning tank for acid cleaning, and finally placed in clean water for ultrasonic cleaning.
3. The insulation powder dipping process for busbar according to claim 2 is characterized in that: The pH value of the solution in the alkaline washing tank is 9-11, the pH value of the solution in the acid washing tank is 2-4, the temperature of the solution in the alkaline washing tank is 65-75° C., and the cleaning time each time is 5-10 minutes.
4. The insulation powder dipping process for busbar according to claim 1 is characterized in that: The oven baking temperature in step S3 is 105-125° C., and the baking time is 20-30 minutes.
5. The insulation powder dipping process for busbar according to claim 1 is characterized in that: The protective cover in step S4 is an aluminum foil cover, and the adhesive tape is a glass fiber tape.
6. The insulation powder dipping process for busbar according to claim 1 is characterized in that: The specific method of sandblasting in step S5 is: placing the busbars on the conveyor belt and sending them into the sandblasting machine in sequence, turning the busbars over for a second sandblasting after one sandblasting, and removing dust from the busbars after sandblasting with an air gun.
7. The insulation powder dipping process for busbars according to claim 6, characterized in that: The conveying frequency of the conveyor belt is 25-35 mm / S, the swing frequency of the sandblasting gun is 40-50 Hz, and the flow rate of the sandblasting gun is 0.5-1 m 3 / min, the sandblasting particles are 80 mesh brown corundum sand.
8. The insulation powder dipping process for busbar according to claim 1, characterized in that: After the busbar is dipped in powder, the powder thickness is within 0.34-0.37 mm.
9. The insulation powder dipping process for busbar according to claim 1, characterized in that: After the powder dipping is completed, it also includes checking whether there are impurities on the surface of the mother bar powder and screening the powder in time.
10. The insulation powder dipping process for busbar according to claim 1, characterized in that: The temperature of the large oven in step S8 is 170-190° C., the speed of the large oven is 22 Hz, and the heating and curing time of a single product is at least 20 minutes.