Copper bar cable easy to bend

Abstract

The invention discloses an easy-to-bend copper bar cable which comprises a flat copper bar conductor with the section thickness of 2.95 mm to 3.05 mm, the section width of 15.90 mm to 16.10 mm and the sectional area of 48 mm < 2 >, and an insulating layer which is made of a nylon material and wraps the copper bar conductor, the average thickness of the insulating layer is 0.55 mm to 0.65 mm, the minimum local thickness of the insulating layer is larger than or equal to 0.48 mm, the height of the outer contour of the insulating layer is 4.2 mm, and the thickness of the outer contour of the insulating layer is 4.2 mm. The width of the insulating layer is 17.2 mm, and the surface roughness Ra of the insulating layer is less than or equal to 0.8 [mu] m. The electric connector has the characteristics of temperature resistance, aging resistance and chemical corrosion resistance, supports customized designs such as end stamping and tin plating, is convenient to mount, reduces the occupied space by 30%, and remarkably improves the reliability and durability of electrical connection and the system integration efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of power transmission, in particular to an easily bendable copper busbar cable. Background Art

[0002] In HEVs, EVs, and ESS systems, the connections between battery cells and electrical components must meet requirements such as high current carrying capacity, low resistance loss, and spatial adaptability. Traditional busbars typically use multi-stranded wire or rigid copper busbars, which present the following issues: 1. Poor spatial adaptability: Rigid copper busbars are difficult to bend, requiring custom, complex shapes, increasing installation difficulty and cost; 2. Complex process: Bending large-section wires requires specialized equipment and can easily cause insulation cracking; 3. Bulky size: Multi-strand cables take up a lot of space, affecting the aesthetics of equipment layout and heat dissipation efficiency.

[0003] Although existing technologies use flexible cables, their limited cross-sectional area makes them incapable of meeting the requirements of high-current scenarios. Therefore, a new connection solution with high current carrying capacity, ease of processing, and spatial adaptability is urgently needed. Summary of the Invention

[0004] The purpose of the present invention is to provide a copper busbar cable that is easy to bend, thereby solving the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: an easily bendable copper busbar cable, comprising:

[0006] Flat copper busbar conductor with a cross-sectional thickness of 2.95mm-3.05mm and a cross-sectional width of 15.90mm-16.10mm, and a cross-sectional area of 48mm 2 ;

[0007] An insulating layer made of nylon covering the copper busbar conductor, wherein the average thickness of the insulating layer is 0.55 mm to 0.65 mm, and the minimum local thickness is ≥ 0.48 mm;

[0008] The height of the outer contour of the insulating layer is 4.2 mm, the width of the insulating layer is 17.2 mm, and the surface roughness Ra of the insulating layer is ≤ 0.8 μm.

[0009] Preferably, the copper busbar conductor is made of T2 grade pure copper, and the Vickers hardness of the copper busbar conductor after annealing is between 45-55, and the elongation is ≥30%.

[0010] Preferably, the insulation layer has a melt index of 7.5 g / 10 min-8.5 g / 10 min-8.5, a long-term operating temperature range of -40°C to 125°C, and identification information is printed on the surface of the insulation layer.

[0011] Preferably, the end of the copper busbar conductor can be customized into a U-shaped groove, an L-shaped bend or a punched hole structure, and the surface of the end of the copper busbar conductor is tinned to enhance the reliability of welding or bolt fixing.

[0012] Preferably, the DC resistance of the cable is less than or equal to 0.4 mΩ / m, and the insulation resistance is greater than or equal to 100 MΩ·km.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] The present invention adopts a cross-sectional area of 48mm 2 The annealed copper busbar conductor is used as the conductor, and its ductility is improved through cold rolling and annealing processes. It supports multi-directional bending and can adapt to complex spatial layouts. The insulation layer is made of high-temperature resistant silicone rubber material, which is evenly coated with the copper busbar through a co-extrusion process, and has the characteristics of temperature resistance, aging resistance and chemical corrosion resistance. Its innovation lies in combining the high current-carrying capacity of the flat copper busbar with the flexible insulation advantages of silicone rubber, which solves the space limitations and process complexity problems of traditional busbar connections. At the same time, it supports customized designs such as end stamping and tinning, which is easy to install and reduces space occupancy by 30%, significantly improving the reliability, durability and system integration efficiency of electrical connections. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a cross-sectional view of the present invention. DETAILED DESCRIPTION

[0016] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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 making creative efforts are within the scope of protection of the present invention.

[0017] In the description of the present invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "back," "left," "right," "horizontal," "vertical," "top," "inner," and "outer" and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations of the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0018] See also Figure 1 The present invention provides an embodiment of a bendable copper busbar cable, comprising the following production steps:

[0019] Step 1: Select a copper busbar conductor 1, using T2 grade pure copper, where the purity of the T2 grade copper busbar conductor is greater than or equal to 99.9%, and process it into a flat copper busbar conductor 1 with a cross-sectional thickness of 2.95mm-3.05mm and a cross-sectional width of 15.90mm-16.10mm through a cold rolling process. The cross-sectional area of the flat copper busbar conductor is 48mm 2 , the surface roughness after cold rolling is Ra≤0.5μm to ensure the uniformity of subsequent insulation layer coating.

[0020] Step 2: Annealing treatment: Place the copper busbar conductor 1 in a nitrogen atmosphere furnace with a nitrogen purity greater than or equal to 99.99%, heat it to 440°C to 460°C and hold it for 30 minutes, then water-quench it. After annealing, the copper busbar has a Vickers hardness of 45-55, an elongation greater than or equal to 30%, and a grain size of ASTM grade 8 or above, significantly improving its bending performance.

[0021] Step 3: Select insulating material, using nylon particles with a melt index of 7.5g / 10min to 8.5g / 10min, and pre-dry them at 80°C for 4 hours to remove moisture.

[0022] Step 4: Co-extrusion of the insulation layer: preheat the annealed copper busbar to between 75°C and 85°C, feed it into the feed port of the twin-screw extruder, heat the nylon particles to between 225°C and 235°C in the extruder and melt them, and evenly coat the surface of the copper busbar through the co-extrusion die to form the insulation layer 2; the extrusion pressure is controlled at 8 to 12 MPa, and the pulling speed is 1.5 to 2.0 m / min to ensure that the thickness of the insulation layer 2 is uniform.

[0023] Step 5: Thickness control: Use a laser thickness gauge to monitor the thickness of the insulation layer 2 in real time. The average thickness is 0.60mm, the minimum local thickness is at least 0.48mm, and the outer contour dimensions are 4.2mm wide and 17.2mm wide. The surface roughness Ra ≤ 0.8μm, without burrs or bubbles.

[0024] Step 6: Cooling and shaping. The extruded cable is quickly cooled and shaped in a water cooling tank with a water temperature of 18°C to 22°C to avoid excessive crystallization of the nylon material and resulting in brittleness.

[0025] Step 7: End processing: Cut the cable to a customized length, and use a stamping process to form a U-shaped groove or L-shaped bend structure on the end. The surface of the cable end is tinned with a coating thickness of greater than or equal to 5μm to enhance the reliability of welding or bolting.

[0026] Step 8: Pass the electrical performance test:

[0027] DC resistance: tested using the four-wire method (GB / T 3048.4), resistance value ≤ 0.4mΩ / m (20°C);

[0028] Withstand voltage test: Apply AC 3000V voltage for 5 minutes, no breakdown or flashover phenomenon;

[0029] Insulation resistance: tested at 500V DC, insulation resistance ≥ 100MΩ·km.

[0030] Mechanical properties test:

[0031] Bending fatigue: 1000 bending cycles at an angle of ±90°, with no cracks or peeling of the insulation layer;

[0032] Tensile strength: copper busbar tensile strength ≥ 200N / mm 2 , ensuring that it is not easily deformed during installation.

[0033] Furthermore, identification information is printed on the surface of the insulating layer 2. The identification information may include manufacturer code, voltage rating, production batch, etc., so that users can quickly understand basic information about the cable.

[0034] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A copper busbar cable that is easy to bend, characterized by: include: Flat copper busbar conductor with a cross-sectional thickness of 2.95mm-3.05mm and a cross-sectional width of 15.90mm-16.10mm, and a cross-sectional area of 48mm 2 ; An insulating layer made of nylon covering the copper busbar conductor, wherein the average thickness of the insulating layer is 0.55 mm to 0.65 mm, and the minimum local thickness is ≥ 0.48 mm; The height of the outer contour of the insulating layer is 4.2 mm, the width of the insulating layer is 17.2 mm, and the surface roughness Ra of the insulating layer is ≤ 0.8 μm.

2. The easily bendable copper busbar cable according to claim 1, characterized in that: The copper busbar conductor is made of T2 grade pure copper, and the Vickers hardness of the copper busbar conductor after annealing is between 45-55, and the elongation is ≥30%.

3. The easily bendable copper busbar cable according to claim 1, characterized in that: The insulating layer has a melt index of 7.5g / 10min-8.5g / 10min-8.5, a long-term operating temperature range of -40°C to 125°C, and identification information is printed on the surface of the insulating layer.

4. The easily bendable copper busbar cable according to claim 1, characterized in that: The ends of the copper busbar conductors can be customized into U-shaped grooves, L-shaped bends or punched hole structures, and the surfaces of the ends of the copper busbar conductors are tin-plated to enhance the reliability of welding or bolt fixing.

5. The easily bendable copper busbar cable according to any one of claims 1 to 4, characterized in that: The DC resistance of the cable is less than or equal to 0.4 mΩ / m, and the insulation resistance is greater than or equal to 100 MΩ·km.

Images