Busbar using conductive extrusion molding material as shield

Abstract

The invention relates to the technical field of electric power conductive parts, in particular to a busbar using a conductive extrusion molding material as a shield, which comprises the following steps: S1, selecting a high-voltage insulating conductive material; s2, raw material pretreatment quality detection; s3, carrying out extrusion molding on the high-voltage insulating layer; s4, extruding and coating the conductive shielding layer; s5, carrying out secondary extrusion molding on the double-layer insulation structure; s6, processing the cutting edge of the busbar; s7, bending and forming the busbar; s8, peeling and punching the busbar; and S9, packaging and quality assurance testing. The 70% high-voltage insulating layer (crosslinked polyethylene) is used for providing the excellent dielectric strength of at least 35 kV / mm, electric shock and short circuit accidents are effectively prevented, safe operation of a power system is ensured, the 30% high-purity copper or aluminum alloy conductive shielding layer achieves the electromagnetic shielding effectiveness larger than or equal to 80 dB, electromagnetic interference (EMI) is remarkably inhibited, and the service life of the cable is prolonged. The influence of electromagnetic noise on surrounding equipment is reduced, and the stability and reliability of the system are improved.

Description

Technical Field

[0001] The invention relates to the technical field of electric power conductive parts, and in particular to a busbar using conductive extruded plastic material for shielding. Background Art

[0002] As an important conductive element in the power system, the busbar is widely used in high-voltage power transmission, electrical equipment connection, electric vehicle battery packs and other complex power systems. Its main function is to transmit electrical energy and ensure the stable operation of the system. With the continuous improvement of modern industry's requirements for electrical system performance, especially in complex environments with high voltage and high current, the busbar, in addition to having high conductivity and mechanical strength, must also meet the requirements of electromagnetic shielding to effectively suppress electromagnetic interference (EMI) and improve the reliability and stability of the system. The demand for lightweight design in the fields of electric vehicles, power equipment, etc. is increasing, which requires the shielding structure of the busbar to reduce weight as much as possible while maintaining excellent performance, in order to meet the market demand for efficient, lightweight and energy-saving products. However, the shielding method of traditional busbars often relies on metal materials, which are heavy and complex in processing, and have gradually become difficult to meet the needs of these emerging markets.

[0003] Existing electromagnetic shielding busbars are now gradually adopting the method of copper conductor weaving + copper foil / aluminum foil winding and coating to achieve shielding. The metal material of the shielding layer makes the overall weight of the busbar larger, and it gradually loses its competitiveness in the field of pursuing lightweight such as electric vehicles. The traditional shielding busbar is usually composed of an insulating layer, a braided copper wire, a copper foil or aluminum foil winding coating layer and a sheath layer, a total of four layers. This complex multi-layer design leads to a lengthy production process, which affects production efficiency and also increases manufacturing costs. In the process of combining the multi-layer structure, the traditional busbar is prone to performance degradation due to bubbles or cracks, and the stability in high or low temperature environments is poor, which cannot fully meet the safety and efficiency requirements of high-voltage power systems. Therefore, we provide a busbar using conductive extruded materials for shielding. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, the first object of the present invention is to provide a busbar using conductive extruded material for shielding, so as to solve the above-mentioned problems in the background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A busbar using conductive extruded material as shielding comprises the following steps:

[0007] S1. Selection of high voltage insulating and conductive materials;

[0008] S2. Raw material pretreatment quality inspection;

[0009] S3, high voltage insulation layer extrusion molding;

[0010] S4, conductive shielding layer extrusion coating;

[0011] S5, double-layer insulation structure secondary extrusion;

[0012] S6, busbar cutting edge processing;

[0013] S7, busbar bending and forming;

[0014] S8, peel and punch holes on the busbar;

[0015] S9. Packaging and quality assurance testing.

[0016] The present invention is further configured as follows: in the step S1, in selecting the high voltage insulating conductive material:

[0017] S1.1. Select appropriate high-voltage insulation materials and conductive extruded materials. The high-voltage insulation materials shall be polyethylene (PE), cross-linked polyethylene (XLPE) or polyurethane (PU), and their dielectric strength shall meet the requirement of at least 35kV / mm; the conductive extruded materials shall be high-purity copper (≥99.9%), aluminum (≥99.5%), copper alloy (copper-tin-zinc alloy) or aluminum alloy (6061 aluminum alloy), as well as copper-aluminum composite materials;

[0018] S1.2. Carry out strict performance tests on the selected materials. High-voltage insulation materials must pass dielectric strength test (≥35kV / mm), tensile strength test (≥20MPa) and thermal stability test (stable performance under -40℃ to +120℃ environment); conductive materials must pass chemical composition analysis (using X-ray fluorescence spectrometer), conductivity test (≥5.8×10^7S / mforcopper) and mechanical tensile test (elongation at break ≥5%) to confirm that their purity and conductivity meet the design requirements;

[0019] S1.3. According to the production formula, the high-voltage insulating material and the conductive material are accurately weighed in proportion, with the insulating layer accounting for 70% of the total thickness and the shielding layer accounting for 30%. The batching process must be carried out in a dust-free environment, using clean room equipment to prevent impurities from mixing in. After mixing evenly, the materials are loaded into the barrel of the extruder in batches;

[0020] S1.4. Pre-treat the materials. High-voltage insulating materials need to be dried in a drying room at 60°C to 80°C for 6 to 8 hours to remove moisture. Conductive extruded materials need to be heated to their melting temperature in a preheating furnace (the melting point of copper is 1085°C, and the actual extrusion temperature is controlled at around 900°C) for preheating. The pretreated materials need to be stored in a constant temperature and humidity environment (relative humidity ≤50%, temperature maintained at 25°C).

[0021] The present invention is further configured as follows: in the step S2, raw material pretreatment quality detection:

[0022] S2.1. Use a high-precision extruder to extrude the high-voltage insulation layer, adjust the temperature of the extruder to the melting temperature range of the high-voltage insulation material (the melting temperature of XLPE is about 160°C to 200°C), control the pressure between 15 and 25 MPa, and set the extrusion speed to 1 to 2 m / min;

[0023] S2.2. The pre-treated high-voltage insulating material is evenly fed into the barrel of the extruder through the hopper. The automatic feeding equipment can accurately control the input speed of the material to avoid unstable extrusion caused by excessive or insufficient material, and monitor the flow state of the material in the barrel in real time;

[0024] S2.3. The high-voltage insulating material is pushed by the screw, melted and extruded through the heating zone, and the initial shape of the insulating layer is formed through a customized mold. The mold design must meet the cross-sectional requirements of the busbar (circular, rectangular or other specific shapes), and the material flow must be kept stable during the extrusion process;

[0025] S2.4. During the extrusion process, laser measurement is used to monitor the thickness and width of the extruded material in real time. The screw speed and mold temperature of the extruder are automatically adjusted according to the measurement data through closed-loop control to ensure the dimensional accuracy of the insulation layer. If the measurement data deviation exceeds the preset range, an alarm will be automatically issued and adjustments will be made;

[0026] S2.5. The high-voltage insulation layer after extrusion needs to be initially cooled to fix its shape. The extrudate is guided to the cooling trough by a conveyor belt, and the insulation layer is quickly cooled to below 50°C by circulating cooling water. The water flow rate and temperature need to be controlled during the cooling process.

[0027] The present invention is further configured as follows: in the step S3, in the extrusion molding of the high voltage insulation layer:

[0028] S3.1. Equip high voltage insulation layer extrusion equipment, including preheating furnace, screw extruder and customized mold. The preheating furnace must have a temperature control accuracy of ±1°C;

[0029] S3.2. Evenly feed the pre-treated high-voltage insulating material into the extruder barrel, and gradually push the material to the heating zone through the rotation of the screw to ensure that the material is fully mixed and flows evenly during the melting process to avoid local overheating or the generation of unmelted areas;

[0030] S3.3, adjust the working parameters of the extruder, including screw speed, extrusion pressure and mold temperature, and optimize the parameters to obtain a stable extrusion flow and uniform insulation layer thickness according to material properties and production requirements;

[0031] S3.4, Extrusion molding is performed through a mold. The design of the mold must ensure that the geometric dimensions and surface quality of the insulating layer meet the design requirements. During the extrusion process, vibration equipment is used to reduce the retention of material in the mold;

[0032] S3.5. After extrusion, the high-voltage insulation layer enters the cooling stage through a conveyor. The temperature of the insulation layer is quickly reduced to below 50°C by circulating constant temperature cooling water to fix its shape and size. The temperature and shape of the insulation layer need to be monitored during the cooling process.

[0033] The present invention is further configured as follows: in the step S4, in the extrusion coating of the conductive shielding layer:

[0034] S4.1. Preheat the conductive material by using a preheating furnace to heat the high-purity copper or aluminum alloy extruded material to near its melting temperature;

[0035] S4.2. Adjust the extruder parameters, including extrusion temperature, pressure and speed, to suit the physical properties of the conductive shielding material. The extrusion temperature of the conductive material needs to be higher than that of the insulating material to ensure that the shielding layer can be smoothly covered on the insulating layer.

[0036] S4.3, extruding the conductive shielding material through an extruder to form a uniform shielding layer in the multilayer structure, using a twin-screw extruder during the extrusion process to ensure uniform distribution and stable flow of the conductive material;

[0037] S4.4. After the shielding layer is extruded, it is cooled to room temperature quickly to fix the shape and size of the shielding layer. During the cooling process, the shielding layer and the insulating layer are firmly bonded;

[0038] S4.5. Perform quality inspection on the conductive shielding layer after extrusion coating, including shielding layer thickness measurement, conductivity test (resistivity ≤ 1.68×10^-8Ω·mforcopper) and visual inspection (no bubbles, cracks or uneven areas) to ensure that the shielding layer meets the design requirements.

[0039] The present invention is further configured as follows: in the step S5, in the secondary extrusion of the double-layer insulation structure:

[0040] S5.1. remelting the preliminarily extruded double-layer structure (including the high-voltage insulation layer and the conductive shielding layer), and remelting the double-layer structure at a high temperature using a twin-screw extruder;

[0041] S5.2. Adjust the parameters of the secondary extrusion equipment, including extrusion temperature (XLPE about 160℃ to 200℃), extrusion pressure (20 to 30MPa) and extrusion speed (1.5 to 2.5 m / min) to ensure uniform flow of materials and firmness of interlayer bonding during the secondary extrusion process;

[0042] S5.3. Use customized molds for secondary extrusion molding. The mold design must ensure the geometric dimensions of the double-layer insulation structure and the tight bonding between the layers, without delamination or bubbles. The mold material must have good high temperature resistance and low friction coefficient;

[0043] S5.4, cooling and size control, using a constant temperature cooling tank to quickly cool the double-layer structure after secondary extrusion to below 50°C to fix its final shape and size, and using closed-loop control to monitor the temperature and shape of the double-layer structure during the cooling process;

[0044] S5.5. Perform quality inspection on the double-layer insulation structure after secondary extrusion, including interlayer bonding strength test, insulation performance test (dielectric strength ≥ 35kV / mm) and visual inspection (no bubbles, cracks or uneven areas).

[0045] The present invention is further configured as follows: in the step S6, in the busbar cutting edge processing:

[0046] S6.1. Prepare cutting equipment, including high-precision automatic cutting machines, equipped with cutting dies and cutters suitable for busbar sections. The cutting machines must have high repeatability (error ≤ 0.1 mm);

[0047] S6.2. Write and execute the cutting program, set the cutting parameters (cutting speed, tool pressure and cutting path) of the cutting machine according to the designed length and specifications of the busbar;

[0048] S6.3. The double-layer insulation structure formed by secondary extrusion is conveyed to the cutting machine through a conveying device to ensure the stable positioning and movement of the material during the cutting process to avoid deviation or damage during the cutting process;

[0049] S6.4, perform cutting operation, the cutting machine automatically completes the cutting of the busbar according to the preset program, ensuring the flatness of the cutting surface and the accuracy of the cutting length, using laser cutting or water jet cutting technology;

[0050] S6.5. Perform edge processing after cutting, including deburring and edge grinding, using automatic grinding equipment or manual grinding tools to ensure that the busbar edge is smooth without sharp edges or residues;

[0051] S6.6. Perform quality inspection on the busbar after cutting and edge processing, including cutting length measurement, edge finish inspection and appearance inspection.

[0052] The present invention is further configured as follows: in the step S7, in the busbar bending forming process:

[0053] S7.1. Design the bending mold. According to the geometric shape and application requirements of the busbar, customize the shape and size of the bending mold (right-angle bending, curve bending). The mold material must have high wear resistance and good elasticity;

[0054] S7.2. Calibrate the bending equipment, use a high-precision CNC bending machine (CNC bending machine), and set the bending angle, bending radius and bending torque;

[0055] S7.3. Fix the cut busbar on the workbench of the bending machine and use a positioning fixture to ensure the stability and accurate positioning of the busbar during the bending process;

[0056] S7.4, perform bending operation, apply bending torque step by step according to the preset bending procedure, so that the busbar is formed according to the design requirements, and monitor the bending angle and torque in real time during the bending process;

[0057] S7.5. Post-bending inspection shall be carried out, including bending angle measurement, surface quality inspection of the bending part (no cracks, deformation or residual stress) and integrity inspection of the overall structure to ensure that the busbar after bending meets the design specifications and quality standards.

[0058] The present invention is further configured as follows: in the step S8, the busbar peeling and punching process:

[0059] S8.1. Equip peeling equipment, including automatic peeling machines or manual peeling tools, to ensure that the insulation layer on the busbar surface can be effectively removed to expose the conductive shielding layer. The peeling equipment must have adjustable cutting depth and speed;

[0060] S8.2. Perform the peeling operation, fix the bent busbar on the workbench of the peeling equipment, and gradually remove the insulation layer according to the preset peeling path and depth to ensure that the conductive shielding layer is exposed intact;

[0061] S8.3. Design the punching position, quantity and size according to the electrical connection requirements of the busbar. The punching design needs to consider the conductivity and mechanical strength;

[0062] S8.4. Configure drilling equipment, including automatic drilling machine or CNC drilling machine, and set drilling parameters (drilling speed, pressure and coolant flow);

[0063] S8.5. Perform the punching operation, automatically or manually according to the design drawings and the punching procedure, and monitor the quality of the holes in real time during the punching process to avoid deviation or uneven hole diameter;

[0064] S8.6. Perform quality inspection on the busbar after peeling and punching, including checking the integrity of the conductive shielding layer, measuring the punching position and size, and conducting performance test (conductive resistance test).

[0065] The present invention is further configured as follows: in the step S9, packaging and quality assurance test:

[0066] S9.1. Prepare packaging materials, including anti-static packaging bags, protective filling materials (bubble film, foam plastics) and label printing equipment. The packaging materials must have good anti-static properties and protective capabilities;

[0067] S9.2. Set up the packaging process, classify and number the peeled and punched busbars according to the specifications, ensure that each section of busbar has a unique identification mark, and use automatic sorting devices to improve packaging efficiency and accuracy;

[0068] S9.3. Perform packaging operations, place the busbars into anti-static packaging bags, use protective filling materials to fill the gaps to prevent the busbars from moving or colliding during the packaging process and causing damage, and perform a final appearance inspection before sealing;

[0069] S9.4. Label the busbars using barcode or QR code labels to record the production information (production date, batch number, specification parameters) of each busbar segment, and firmly affix the labels to the outside of the package.

[0070] S9.5. Perform final quality assurance and various tests, including: Electrical performance test: Measure the conductive resistance of the busbar to ensure that it meets the design standards (resistivity ≤ 1.68×10^-8Ω·mforcopper):

[0071] Mechanical performance test: Test the tensile strength, bending strength and wear resistance of the busbar to ensure its reliability in practical applications;

[0072] Insulation performance test: verify the dielectric strength of the double-layer insulation structure to ensure its insulation performance under high voltage environment (≥35kV / mm);

[0073] Shielding effectiveness test: Evaluate the shielding effectiveness of the conductive shielding layer to ensure that it can effectively shield electromagnetic interference (EMI) and meet relevant standard requirements;

[0074] S9.6. Conduct final review on busbars that have passed all quality tests, generate quality reports, and classify and package qualified busbars according to order requirements for shipment.

[0075] Beneficial Effects

[0076] Compared with the known public technology, the technical solution provided by the present invention has the following beneficial effects:

[0077] 1. The present invention provides an excellent dielectric strength of at least 35kV / mm by using 70% high-voltage insulation layer (cross-linked polyethylene), effectively preventing electric shock and short-circuit accidents, and ensuring the safe operation of the power system. The 30% high-purity copper or aluminum alloy conductive shielding layer achieves an electromagnetic shielding effectiveness of ≥80dB, significantly suppresses electromagnetic interference (EMI), reduces the impact of electromagnetic noise on surrounding equipment, and improves the stability and reliability of the system. The high conductivity of the conductive material (copper ≥5.8×10^7S / m) ensures low resistance and high-efficiency electrical connection, optimizes power transmission performance, reduces energy loss, reduces the mass of the shielded busbar, and meets the market demand for lightweight electric vehicles, thereby improving its practicality in actual use.

[0078] 2. The present invention ensures the firm combination of the insulating layer and the shielding layer through multiple extrusion molding processes, avoids the generation of bubbles and cracks, and ensures the performance stability and mechanical strength in high and low temperature environments. The precise cutting, bending, peeling and punching processes give the busbar good flexibility and adaptability, which is convenient for installation and connection in various complex power systems. Through strict packaging and quality assurance tests, each section of the busbar meets high standards of electrical and mechanical performance requirements before leaving the factory, providing reliable product guarantees, meeting the dual needs of high-voltage power systems for safety and efficiency, and significantly improving the performance and reliability of the overall power transmission system. It meets different structural forms and working conditions, and the structure of multiple soft busbars stacked together can be used in dynamic environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 This is a schematic diagram of the inner lining arrangement of a busbar using conductive extruded material for shielding according to the present invention;

[0080] Figure 2 A schematic diagram of stacking conductor sheets of a busbar shielded by conductive extruded plastic material according to the present invention;

[0081] Figure 3 The present invention is a schematic diagram of the processing flow of a busbar using conductive extruded material for shielding. DETAILED DESCRIPTION

[0082] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are 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.

[0083] The present invention will be further described below in conjunction with the embodiments.

[0084] Example 1

[0085] like Figure 1 - Figure 3 As shown, the present invention provides a technical solution: a busbar using conductive extruded material as shielding, comprising the following steps:

[0086] S1. Selection of high voltage insulating and conductive materials;

[0087] S2. Raw material pretreatment quality inspection;

[0088] S3, high voltage insulation layer extrusion molding;

[0089] S4, conductive shielding layer extrusion coating;

[0090] S5, double-layer insulation structure secondary extrusion;

[0091] S6, busbar cutting edge processing;

[0092] S7, busbar bending and forming;

[0093] S8, peel and punch holes on the busbar;

[0094] S9. Packaging and quality assurance testing.

[0095] In the step S1, selecting high voltage insulating conductive materials:

[0096] S1.1. Select appropriate high-voltage insulation materials and conductive extruded materials. The high-voltage insulation materials shall be polyethylene (PE), cross-linked polyethylene (XLPE) or polyurethane (PU), and their dielectric strength shall meet the requirement of at least 35kV / mm; the conductive extruded materials shall be high-purity copper (≥99.9%), aluminum (≥99.5%), copper alloy (copper-tin-zinc alloy) or aluminum alloy (6061 aluminum alloy), as well as copper-aluminum composite materials;

[0097] S1.2. Carry out strict performance tests on the selected materials. High-voltage insulation materials must pass dielectric strength test (≥35kV / mm), tensile strength test (≥20MPa) and thermal stability test (stable performance under -40℃ to +120℃ environment); conductive materials must pass chemical composition analysis (using X-ray fluorescence spectrometer), conductivity test (≥5.8×10^7S / mforcopper) and mechanical tensile test (elongation at break ≥5%) to confirm that their purity and conductivity meet the design requirements;

[0098] S1.3. According to the production formula, the high-voltage insulating material and the conductive material are accurately weighed in proportion, with the insulating layer accounting for 70% of the total thickness and the shielding layer accounting for 30%. The batching process must be carried out in a dust-free environment, using clean room equipment to prevent impurities from mixing in. After mixing evenly, the materials are loaded into the barrel of the extruder in batches;

[0099] S1.4. Pre-treat the materials. High-voltage insulating materials need to be dried in a drying room at 60°C to 80°C for 6 to 8 hours to remove moisture. Conductive extruded materials need to be heated to their melting temperature in a preheating furnace (the melting point of copper is 1085°C, and the actual extrusion temperature is controlled at around 900°C) for preheating. The pretreated materials need to be stored in a constant temperature and humidity environment (relative humidity ≤50%, temperature maintained at 25°C).

[0100] In the step S2, raw material pretreatment quality inspection:

[0101] S2.1. Use a high-precision extruder to extrude the high-voltage insulation layer, adjust the temperature of the extruder to the melting temperature range of the high-voltage insulation material (the melting temperature of XLPE is about 160°C to 200°C), control the pressure between 15 and 25 MPa, and set the extrusion speed to 1 to 2 m / min;

[0102] S2.2. The pre-treated high-voltage insulating material is evenly fed into the barrel of the extruder through the hopper. The automatic feeding equipment can accurately control the input speed of the material to avoid unstable extrusion caused by excessive or insufficient material, and monitor the flow state of the material in the barrel in real time;

[0103] S2.3. The high-voltage insulating material is pushed by the screw, melted and extruded through the heating zone, and the initial shape of the insulating layer is formed through a customized mold. The mold design must meet the cross-sectional requirements of the busbar (circular, rectangular or other specific shapes), and the material flow must be kept stable during the extrusion process;

[0104] S2.4. During the extrusion process, laser measurement is used to monitor the thickness and width of the extruded material in real time. The screw speed and mold temperature of the extruder are automatically adjusted according to the measurement data through closed-loop control to ensure the dimensional accuracy of the insulation layer. If the measurement data deviation exceeds the preset range, an alarm will be automatically issued and adjustments will be made;

[0105] S2.5. The high-voltage insulation layer after extrusion needs to be initially cooled to fix its shape. The extrudate is guided to the cooling trough by a conveyor belt, and the insulation layer is quickly cooled to below 50°C by circulating cooling water. The water flow rate and temperature need to be controlled during the cooling process.

[0106] In the step S3, high voltage insulation layer extrusion molding:

[0107] S3.1. Equip high voltage insulation layer extrusion equipment, including preheating furnace, screw extruder and customized mold. The preheating furnace must have a temperature control accuracy of ±1°C;

[0108] S3.2. Evenly feed the pre-treated high-voltage insulating material into the extruder barrel, and gradually push the material to the heating zone through the rotation of the screw to ensure that the material is fully mixed and flows evenly during the melting process to avoid local overheating or the generation of unmelted areas;

[0109] S3.3, adjust the working parameters of the extruder, including screw speed, extrusion pressure and mold temperature, and optimize the parameters to obtain a stable extrusion flow and uniform insulation layer thickness according to material properties and production requirements;

[0110] S3.4, Extrusion molding is performed through a mold. The design of the mold must ensure that the geometric dimensions and surface quality of the insulating layer meet the design requirements. During the extrusion process, vibration equipment is used to reduce the retention of material in the mold;

[0111] S3.5. After extrusion, the high-voltage insulation layer enters the cooling stage through a conveyor. The temperature of the insulation layer is quickly reduced to below 50°C by circulating constant temperature cooling water to fix its shape and size. The temperature and shape of the insulation layer need to be monitored during the cooling process.

[0112] In the step S4, extrusion coating of the conductive shielding layer:

[0113] S4.1. Preheat the conductive material by using a preheating furnace to heat the high-purity copper or aluminum alloy extruded material to near its melting temperature;

[0114] S4.2. Adjust the extruder parameters, including extrusion temperature, pressure and speed, to suit the physical properties of the conductive shielding material. The extrusion temperature of the conductive material needs to be higher than that of the insulating material to ensure that the shielding layer can be smoothly covered on the insulating layer.

[0115] S4.3, extruding the conductive shielding material through an extruder to form a uniform shielding layer in the multilayer structure, using a twin-screw extruder during the extrusion process to ensure uniform distribution and stable flow of the conductive material;

[0116] S4.4. After the shielding layer is extruded, it is cooled to room temperature quickly to fix the shape and size of the shielding layer. During the cooling process, the shielding layer and the insulating layer are firmly bonded;

[0117] S4.5. Perform quality inspection on the conductive shielding layer after extrusion coating, including shielding layer thickness measurement, conductivity test (resistivity ≤ 1.68×10^-8Ω·mforcopper) and visual inspection (no bubbles, cracks or uneven areas) to ensure that the shielding layer meets the design requirements.

[0118] In the step S5, the double-layer insulation structure is extruded twice:

[0119] S5.1. remelting the preliminarily extruded double-layer structure (including the high-voltage insulation layer and the conductive shielding layer), and remelting the double-layer structure at a high temperature using a twin-screw extruder;

[0120] S5.2. Adjust the parameters of the secondary extrusion equipment, including extrusion temperature (XLPE about 160℃ to 200℃), extrusion pressure (20 to 30MPa) and extrusion speed (1.5 to 2.5 m / min) to ensure uniform flow of materials and firmness of interlayer bonding during the secondary extrusion process;

[0121] S5.3. Use customized molds for secondary extrusion molding. The mold design must ensure the geometric dimensions of the double-layer insulation structure and the tight bonding between the layers, without delamination or bubbles. The mold material must have good high temperature resistance and low friction coefficient;

[0122] S5.4, cooling and size control, using a constant temperature cooling tank to quickly cool the double-layer structure after secondary extrusion to below 50°C to fix its final shape and size, and using closed-loop control to monitor the temperature and shape of the double-layer structure during the cooling process;

[0123] S5.5. Perform quality inspection on the double-layer insulation structure after secondary extrusion, including interlayer bonding strength test, insulation performance test (dielectric strength ≥ 35kV / mm) and visual inspection (no bubbles, cracks or uneven areas).

[0124] In the step S6, the busbar cutting edge processing:

[0125] S6.1. Prepare cutting equipment, including high-precision automatic cutting machines, equipped with cutting dies and cutters suitable for busbar sections. The cutting machines must have high repeatability (error ≤ 0.1 mm);

[0126] S6.2. Write and execute the cutting program, set the cutting parameters (cutting speed, tool pressure and cutting path) of the cutting machine according to the designed length and specifications of the busbar;

[0127] S6.3. The double-layer insulation structure formed by secondary extrusion is conveyed to the cutting machine through a conveying device to ensure the stable positioning and movement of the material during the cutting process to avoid deviation or damage during the cutting process;

[0128] S6.4, perform cutting operation, the cutting machine automatically completes the cutting of the busbar according to the preset program, ensuring the flatness of the cutting surface and the accuracy of the cutting length, using laser cutting or water jet cutting technology;

[0129] S6.5. Perform edge processing after cutting, including deburring and edge grinding, using automatic grinding equipment or manual grinding tools to ensure that the busbar edge is smooth without sharp edges or residues;

[0130] S6.6. Perform quality inspection on the busbar after cutting and edge processing, including cutting length measurement, edge finish inspection and appearance inspection.

[0131] In the step S7, busbar bending forming process:

[0132] S7.1. Design the bending mold. According to the geometric shape and application requirements of the busbar, customize the shape and size of the bending mold (right-angle bending, curve bending). The mold material must have high wear resistance and good elasticity;

[0133] S7.2. Calibrate the bending equipment, use a high-precision CNC bending machine (CNC bending machine), and set the bending angle, bending radius and bending torque;

[0134] S7.3. Fix the cut busbar on the workbench of the bending machine and use a positioning fixture to ensure the stability and accurate positioning of the busbar during the bending process;

[0135] S7.4, perform bending operation, apply bending torque step by step according to the preset bending procedure, so that the busbar is formed according to the design requirements, and monitor the bending angle and torque in real time during the bending process;

[0136] S7.5. Post-bending inspection shall be carried out, including bending angle measurement, surface quality inspection of the bending part (no cracks, deformation or residual stress) and integrity inspection of the overall structure to ensure that the busbar after bending meets the design specifications and quality standards.

[0137] In the step S8, busbar peeling and punching process:

[0138] S8.1. Equip peeling equipment, including automatic peeling machines or manual peeling tools, to ensure that the insulation layer on the busbar surface can be effectively removed to expose the conductive shielding layer. The peeling equipment must have adjustable cutting depth and speed;

[0139] S8.2. Perform the peeling operation, fix the bent busbar on the workbench of the peeling equipment, and gradually remove the insulation layer according to the preset peeling path and depth to ensure that the conductive shielding layer is exposed intact;

[0140] S8.3. Design the punching position, quantity and size according to the electrical connection requirements of the busbar. The punching design needs to consider the conductivity and mechanical strength;

[0141] S8.4. Configure drilling equipment, including automatic drilling machine or CNC drilling machine, and set drilling parameters (drilling speed, pressure and coolant flow);

[0142] S8.5. Perform the punching operation, automatically or manually according to the design drawings and the punching procedure, and monitor the quality of the holes in real time during the punching process to avoid deviation or uneven hole diameter;

[0143] S8.6. Perform quality inspection on the busbar after peeling and punching, including checking the integrity of the conductive shielding layer, measuring the punching position and size, and conducting performance test (conductive resistance test).

[0144] In the step S9, packaging and quality assurance testing:

[0145] S9.1. Prepare packaging materials, including anti-static packaging bags, protective filling materials (bubble film, foam plastics) and label printing equipment. The packaging materials must have good anti-static properties and protective capabilities;

[0146] S9.2. Set up the packaging process, classify and number the peeled and punched busbars according to the specifications, ensure that each section of busbar has a unique identification mark, and use automatic sorting devices to improve packaging efficiency and accuracy;

[0147] S9.3. Perform packaging operations, place the busbars into anti-static packaging bags, use protective filling materials to fill the gaps to prevent the busbars from moving or colliding during the packaging process and causing damage, and perform a final appearance inspection before sealing;

[0148] S9.4. Label the busbars using barcode or QR code labels to record the production information (production date, batch number, specification parameters) of each busbar segment, and firmly affix the labels to the outside of the package.

[0149] S9.5. Perform final quality assurance and various tests, including: Electrical performance test: Measure the conductive resistance of the busbar to ensure that it meets the design standards (resistivity ≤ 1.68×10^-8Ω·mforcopper):

[0150] Mechanical performance test: Test the tensile strength, bending strength and wear resistance of the busbar to ensure its reliability in practical applications;

[0151] Insulation performance test: verify the dielectric strength of the double-layer insulation structure to ensure its insulation performance under high voltage environment (≥35kV / mm);

[0152] Shielding effectiveness test: Evaluate the shielding effectiveness of the conductive shielding layer to ensure that it can effectively shield electromagnetic interference (EMI) and meet relevant standard requirements;

[0153] S9.6. Conduct final review on busbars that have passed all quality tests, generate quality reports, and classify and package qualified busbars according to order requirements for shipment.

[0154] In this embodiment, the busbar is composed of 70% high-voltage insulation layer (cross-linked polyethylene) and 30% conductive shielding layer (high-purity copper or aluminum alloy). The high-voltage insulation layer provides excellent dielectric strength, ensuring that the insulation performance is maintained under a high-voltage environment of at least 35kV / mm, preventing electric shock and short-circuit accidents. At the same time, the conductive shielding layer effectively shields electromagnetic interference (EMI), reduces the impact of electromagnetic noise on surrounding equipment, and improves the stability and reliability of the system.

[0155] Through strict material selection, pretreatment and multiple extrusion molding processes, the insulation layer and the shielding layer are firmly bonded, and there are no bubbles or cracks between the layers, which ensures the performance stability and mechanical strength of the busbar in high and low temperature environments; the cutting, bending, peeling and punching processes are precisely controlled, so that the busbar has good flexibility and adaptability during installation and use.

[0156] Among them: the mechanical performance test, insulation performance test and shielding effectiveness test performance test standards of standard parts are as follows:

[0157] Mechanical properties test Insulation performance test Shielding effectiveness test tensile strength ≥400MPa Bending Strength ≥300MPa Wear resistance Wear rate ≤5% Dielectric strength ≥35kV / mm Shielding effectiveness ≥80dB

[0158] The present invention,

[0159] In actual use, the busbar made of conductive extruded material plays a key role through the double-layer insulation structure. The 70% high-voltage insulation layer (cross-linked polyethylene) provides excellent dielectric strength, ensuring that the busbar maintains excellent insulation performance in a high-voltage environment of at least 35kV / mm. This layer effectively prevents electric shock and short-circuit accidents and ensures the safe operation of the power system.

[0160] After strict material selection and multiple extrusion molding processes, the insulation layer and the conductive shielding layer are firmly bonded without bubbles or cracks, ensuring performance stability and mechanical strength in high and low temperature environments.

[0161] The conductive shielding layer (accounting for 30%) is made of high-purity copper or aluminum alloy material, and is evenly covered on the outside of the insulation layer through a precise extrusion coating process, with excellent electromagnetic shielding effectiveness (≥80dB). This shielding layer effectively suppresses electromagnetic interference (EMI) and reduces the impact of electromagnetic noise on surrounding equipment, thereby improving the stability and reliability of the entire system. The high conductivity of the conductive material (≥5.8×10^7S / m for copper) ensures low resistance and high efficiency of the busbar in electrical connection, further optimizes power transmission performance, and reduces energy loss.

[0162] The busbar is precisely controlled in subsequent processes such as cutting, bending, peeling and punching to ensure its flexibility and adaptability during installation and use. The high-precision processing technology ensures the dimensional accuracy and edge smoothness of the busbar, making it easy to install and connect in various complex power systems. Through strict packaging and quality assurance tests, it is ensured that each section of busbar meets high standards of electrical and mechanical performance requirements before leaving the factory, providing reliable product protection and meeting the dual needs of high-voltage power systems for safety and efficiency.

[0163] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A busbar using conductive extruded material for shielding, characterized in that: The following steps are involved: S1. Selection of high voltage insulating and conductive materials; S2. Raw material pretreatment quality inspection; S3, high voltage insulation layer extrusion molding; S4, conductive shielding layer extrusion coating; S5, double-layer insulation structure secondary extrusion; S6, busbar cutting edge processing; S7, busbar bending and forming; S8, peel and punch holes on the busbar; S9. Packaging and quality assurance testing.

2. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S1, selecting high voltage insulating conductive materials: S1.

1. Select appropriate high-voltage insulation materials and conductive extruded materials. The high-voltage insulation materials shall be polyethylene, cross-linked polyethylene or polyurethane, and their dielectric strength shall meet the requirement of at least 35kV / mm; the conductive extruded materials shall be high-purity copper, aluminum, copper alloy or aluminum alloy, and copper-aluminum composite materials; S1.

2. Carry out strict performance tests on the selected materials. High-voltage insulation materials must pass dielectric strength test, tensile strength test and thermal stability test; conductive materials must pass chemical composition analysis, conductivity test and mechanical tensile test to confirm that their purity and conductive properties meet the design requirements; S1.

3. According to the production formula, the high-voltage insulating material and the conductive material are accurately weighed in proportion, with the insulating layer accounting for 70% of the total thickness and the shielding layer accounting for 30%. The batching process must be carried out in a dust-free environment, using clean room equipment to prevent impurities from mixing in. After mixing evenly, the materials are loaded into the barrel of the extruder in batches; S1.

4. Pre-treat the materials. High-voltage insulating materials need to be dried in a drying room at 60°C to 80°C for 6 to 8 hours to remove moisture. Conductive extruded materials need to be preheated in a preheating furnace to their melting temperature. The pre-treated materials need to be stored in a constant temperature and humidity environment.

3. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S2, raw material pretreatment quality inspection: S2.

1. Use a high-precision extruder to extrude the high-voltage insulation layer, adjust the temperature of the extruder to the melting temperature range of the high-voltage insulation material, control the pressure between 15 and 25 MPa, and set the extrusion speed to 1 to 2 m / min; S2.

2. The pre-treated high-voltage insulating material is evenly fed into the barrel of the extruder through the hopper. The automatic feeding equipment can accurately control the input speed of the material to avoid unstable extrusion caused by excessive or insufficient material, and monitor the flow state of the material in the barrel in real time; S2.3, the high-voltage insulation material is pushed by the screw, melted in the heating zone and extruded, and the initial shape of the insulation layer is formed by a customized mold. The mold design must meet the cross-sectional requirements of the busbar, and the material flow must be kept stable during the extrusion process; S2.

4. During the extrusion process, a laser measuring device is used to monitor the thickness and width of the extruded material in real time. The screw speed and mold temperature of the extruder are automatically adjusted according to the measurement data through closed-loop control to ensure the dimensional accuracy of the insulation layer. If the measurement data deviation exceeds the preset range, the device will automatically alarm and make adjustments; S2.

5. The high-voltage insulation layer after extrusion needs to be initially cooled to fix its shape. The extrudate is guided to the cooling trough by a conveyor belt, and the insulation layer is quickly cooled to below 50°C using cooling water circulation equipment. The water flow rate and temperature need to be controlled during the cooling process.

4. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S3, high voltage insulation layer extrusion molding: S3.

1. Equip high voltage insulation layer extrusion equipment, including preheating furnace, screw extruder and customized mold. The preheating furnace must have a temperature control accuracy of ±1°C; S3.

2. Evenly feed the pre-treated high-voltage insulating material into the extruder barrel, and gradually push the material to the heating zone through the rotation of the screw to ensure that the material is fully mixed and flows evenly during the melting process to avoid local overheating or the generation of unmelted areas; S3.3, adjust the working parameters of the extruder, including screw speed, extrusion pressure and mold temperature, and optimize the parameters to obtain a stable extrusion flow and uniform insulation layer thickness according to material properties and production requirements; S3.4, Extrusion molding is performed through a die. The design of the die must ensure that the geometric dimensions and surface quality of the insulating layer meet the design requirements. During the extrusion process, vibration equipment is used to reduce the retention of material in the die; S3.

5. After extrusion, the high-voltage insulation layer enters the cooling stage through the conveying equipment. The temperature of the insulation layer is quickly reduced to below 50°C using the constant temperature cooling water circulation equipment to fix its shape and size. The temperature and shape of the insulation layer need to be monitored during the cooling process.

5. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S4, extrusion coating of the conductive shielding layer: S4.

1. Preheat the conductive material by using a preheating furnace to heat the high-purity copper or aluminum alloy extruded material to near its melting temperature; S4.

2. Adjust the extruder parameters, including extrusion temperature, pressure and speed, to suit the physical properties of the conductive shielding material. The extrusion temperature of the conductive material needs to be higher than that of the insulating material to ensure that the shielding layer can be smoothly covered on the insulating layer. S4.3, extruding the conductive shielding material through an extruder to form a uniform shielding layer in the multilayer structure, using a twin-screw extruder during the extrusion process to ensure uniform distribution and stable flow of the conductive material; S4.

4. After the shielding layer is extruded, the cooling equipment is used to quickly cool it down to room temperature to fix the shape and size of the shielding layer. During the cooling process, the shielding layer and the insulating layer are ensured to be firmly bonded; S4.

5. Conduct quality inspection on the conductive shielding layer after extrusion coating, including shielding layer thickness measurement, conductivity performance test and visual inspection, to ensure that the shielding layer meets the design requirements.

6. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S5, the double-layer insulation structure is extruded twice: S5.1, re-melting the preliminarily extruded double-layer structure, and re-melting the double-layer structure at high temperature using a twin-screw extruder; S5.

2. Adjust the parameters of the secondary extrusion equipment, including extrusion temperature, extrusion pressure and extrusion speed, to ensure uniform flow of materials and firmness of interlayer bonding during the secondary extrusion process; S5.

3. Use customized molds for secondary extrusion molding. The mold design must ensure the geometric dimensions of the double-layer insulation structure and the tight bonding between the layers, without delamination or bubbles. The mold material must have good high temperature resistance and low friction coefficient; S5.4, cooling and size control, using a constant temperature cooling tank to quickly cool the double-layer structure after secondary extrusion to below 50°C to fix its final shape and size, and using a closed-loop control device to monitor the temperature and shape of the double-layer structure during the cooling process; S5.

5. Carry out quality inspection on the double-layer insulation structure after secondary extrusion, including interlayer bonding strength test, insulation performance test and visual inspection.

7. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S6, the busbar cutting edge processing: S6.

1. Prepare cutting equipment, including high-precision automatic cutting machines, equipped with cutting dies and knives suitable for busbar sections. The cutting machines must have high repeatability and positioning accuracy; S6.

2. Write and execute the cutting program, and set the cutting parameters of the cutting machine according to the design length and specifications of the busbar; S6.

3. The double-layer insulation structure formed by secondary extrusion is conveyed to the cutting machine through a conveying device to ensure stable positioning and movement of the material during the cutting process to avoid deviation or damage during the cutting process; S6.4, perform cutting operation, the cutting machine automatically completes the cutting of the busbar according to the preset program, ensuring the flatness of the cutting surface and the accuracy of the cutting length, using laser cutting or water jet cutting technology; S6.

5. Perform edge processing after cutting, including deburring and edge grinding, using automatic grinding equipment or manual grinding tools to ensure that the busbar edge is smooth without sharp edges or residues; S6.

6. Perform quality inspection on the busbar after cutting and edge processing, including cutting length measurement, edge finish inspection and appearance inspection.

8. The busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S7, busbar bending forming process: S7.

1. Design the bending mold. Customize the shape and size of the bending mold according to the geometric shape and application requirements of the busbar. The mold material must have high wear resistance and good elasticity; S7.

2. Calibrate the bending equipment, use a high-precision CNC bending machine, and set the bending angle, bending radius and bending torque; S7.

3. Fix the cut busbar on the workbench of the bending machine and use a positioning fixture to ensure the stability and accurate positioning of the busbar during the bending process; S7.4, perform bending operation, apply bending torque step by step according to the preset bending procedure, so that the busbar is formed according to the design requirements, and monitor the bending angle and torque in real time during the bending process; S7.

5. Perform post-bending inspection, including bending angle measurement, surface quality inspection of the bending part and integrity inspection of the overall structure, to ensure that the busbar after bending meets the design specifications and quality standards.

9. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S8, busbar peeling and punching process: S8.

1. Equip peeling equipment, including automatic peeling machines or manual peeling tools, to ensure that the insulation layer on the busbar surface can be effectively removed to expose the conductive shielding layer. The peeling equipment must have adjustable cutting depth and speed; S8.

2. Perform the peeling operation, fix the bent busbar on the workbench of the peeling equipment, and gradually remove the insulation layer according to the preset peeling path and depth to ensure that the conductive shielding layer is exposed intact; S8.

3. Design the punching position, quantity and size according to the electrical connection requirements of the busbar. The punching design needs to consider the conductivity and mechanical strength; S8.

4. Configure drilling equipment, including automatic drilling machines or CNC drilling machines, and set drilling parameters; S8.

5. Perform the punching operation, automatically or manually according to the design drawings and the punching procedure, and monitor the quality of the holes in real time during the punching process to avoid deviation or uneven hole diameter; S8.

6. Perform quality inspection on the busbar after peeling and punching, including checking the integrity of the conductive shielding layer, measuring the punching position and size, and testing the conductive performance.

10. A busbar using conductive extruded material for shielding according to claim 1, characterized in that: In the step S9, packaging and quality assurance testing: S9.

1. Prepare packaging materials, including antistatic packaging bags, protective filling materials and label printing equipment. The packaging materials must have good antistatic properties and protective capabilities; S9.

2. Set up the packaging process, classify and number the peeled and punched busbars according to the specifications, ensure that each section of busbar has a unique identification mark, and use automatic sorting devices to improve packaging efficiency and accuracy; S9.

3. Perform packaging operations, place the busbars into anti-static packaging bags, use protective filling materials to fill the gaps to prevent the busbars from moving or colliding during the packaging process and causing damage, and perform a final appearance inspection before sealing; S9.

4. Label the busbars using barcode or QR code labels to record the production information of each busbar segment and firmly affix the labels to the outside of the package. S9.

5. Perform final quality assurance and various tests, including: Electrical performance test: measure the conductive resistance of the busbar; S9.

6. Conduct final review on busbars that have passed all quality tests, generate quality reports, and classify and package qualified busbars according to order requirements for shipment.

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