High-voltage-resistant CCS busbar connecting piece structure based on laminated insulation design

Abstract

The invention relates to the technical field of busbar connecting pieces, and discloses a laminated insulation design-based high-voltage-resistant CCS busbar connecting piece structure, which comprises an upper insulating layer, a conducting bar I, a middle insulating layer I, a conducting bar II, a middle insulating layer II, an FPC (Flexible Printed Circuit) and a lower insulating layer. According to the technical scheme of the utility model, the upper insulating layer, the first intermediate insulating layer, the second intermediate insulating layer and the lower insulating layer are all designed to be in the stacked design of the multiple layers of PET insulating films, and the insulating characteristics of the PET insulating films and the sufficient insulating distance and creepage distance formed by the stacking of the multiple layers are utilized. The CCS busbar connecting piece structure can effectively block abnormal conduction of current between different conductive parts or between different conductive parts and an external structure, effectively prevents insulation breakdown, provides a reliable insulation barrier for the whole CCS busbar connecting piece structure, meets the high-voltage-resistant use requirement, can enhance the overall mechanical strength of the CCS busbar connecting piece structure, and improves the service life of the CCS busbar connecting piece structure. And the device has the advantages of high reliability, stable structure and good heat dissipation performance.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of busbar connectors, in particular to a high-voltage CCS busbar connector structure based on a laminated insulation design. BACKGROUND

[0002] The high-voltage CCS busbar connector structure based on the laminated insulation design is a key component applied to new energy vehicles, energy storage devices and the like, and used for realizing functions such as high-voltage series-parallel connection of battery cells and signal acquisition, and has advantages of high-voltage resistance, compact structure, high reliability and the like. As a key component for realizing high-voltage series-parallel connection of battery cells and signal acquisition, the performance of the CCS busbar connector directly affects the safety and reliability of the entire battery system.

[0003] In the prior art, the traditional CCS busbar connector usually adopts a single layer of insulation material for insulation isolation, and the insulation effect is poor, and in a high-voltage environment, insulation breakdown and creepage and the like are prone to occur, which affects the safety and reliability of the battery system. Moreover, the connection mode of the layers of the traditional busbar connector lacks effective reinforcement measures, and the overall mechanical strength is insufficient, and in the process of installation and long-term use, the busbar connector is prone to damage such as bending and breaking due to external force, which affects the service life and stability of the busbar connector, and it is difficult to meet the use requirements.

[0004] Therefore, the application provides a high-voltage CCS busbar connector structure based on a laminated insulation design to solve the above problems. SUMMARY

[0005] The application aims to provide a high-voltage CCS busbar connector structure based on a laminated insulation design, which can effectively block abnormal conduction of current between different conductive components or and external structures, effectively prevent insulation breakdown, provide a reliable insulation barrier for the entire CCS busbar connector structure, and can enhance the overall mechanical strength of the CCS busbar connector structure, and has advantages of high reliability, stable structure and good heat dissipation.

[0006] The above technical purpose of the application is achieved by the following technical scheme: the high-voltage CCS busbar connector structure based on the laminated insulation design comprises an upper insulation layer, a conductive row one, an intermediate insulation layer one, a conductive row two, an intermediate insulation layer two, an FPC flexible circuit board and a lower insulation layer, the conductive row one is fixedly connected to the bottom of the upper insulation layer, the intermediate insulation layer one is fixedly connected to the bottom of the conductive row one, the conductive row two is fixedly connected to the bottom of the intermediate insulation layer one, the intermediate insulation layer two is fixedly connected to the bottom of the conductive row two, the FPC flexible circuit board is fixedly connected to the bottom of the intermediate insulation layer two, and the lower insulation layer is fixedly connected to the bottom of the FPC flexible circuit board.

[0007] The further setting of the present application is that the structure size of the conductive row one and the conductive row two is the same, and the conductive row one and the conductive row two are made of high-purity oxygen-free copper material, and the thickness is 3-5mm.

[0008] The further setting of the present application is that the conductive row one and the conductive row two each include a bus bar, a plurality of single mother rows, two connecting ears and two copper terminal wires, the plurality of single mother rows are fixedly installed on the bus bar and are evenly arranged in two rows, the two connecting ears are fixedly installed at two ends of the bus bar respectively, and the two copper terminal wires are fixedly embedded on the corresponding connecting ears.

[0009] The further setting of the present application is that the bus bar and the two connecting ears are integrally formed.

[0010] The further setting of the present application is that the upper insulating layer, the first intermediate insulating layer, the second intermediate insulating layer and the lower insulating layer have the same structure and are each made of 3-6 layers of PET insulating film stacked together, and the thickness of each layer of PET insulating film is 0.2-0.3mm.

[0011] The further setting of the present application is that the bottom of the upper insulating layer is fixedly connected with a plurality of arrayed insulating reinforcing columns, the bottom ends of the insulating reinforcing columns sequentially penetrate the conductive row one, the first intermediate insulating layer, the conductive row two, the second intermediate insulating layer and the FPC flexible circuit board, and the bottom ends of the insulating reinforcing columns are fixedly connected with the top of the lower insulating layer.

[0012] The further setting of the present application is that the insulating reinforcing column is made of polyimide material.

[0013] The further setting of the present application is that the top surface of the upper insulating layer and the bottom surface of the lower insulating layer are each fixedly connected with a plurality of evenly arranged heat dissipation fins.

[0014] The further setting of the present application is that the FPC flexible circuit board is fixedly connected with a temperature sensor and a voltage acquisition terminal, the temperature sensor is a negative temperature coefficient thermistor, and the voltage acquisition terminal is made of elastic copper sheet.

[0015] The further setting of the present application is that the upper insulating layer, the conductive row one, the first intermediate insulating layer, the conductive row two, the second intermediate insulating layer, the FPC flexible circuit board and the lower insulating layer are sequentially bonded and fixed by a high-temperature-resistant adhesive from top to bottom.

[0016] The present application includes at least one of the following beneficial technical effects: The application adopts the laminated design of the upper insulating layer, the first intermediate insulating layer, the second intermediate insulating layer and the lower insulating layer, and uses the insulating properties of the PET insulating film itself and the sufficient insulation distance and creepage distance formed by the multilayer stacking to effectively block the abnormal conduction of the current between different conductive components or and external structures, effectively prevent insulation breakdown, thereby providing a reliable insulation barrier for the entire CCS busbar connecting structure and meeting the high voltage use requirement.

[0017] The application adopts the insulating reinforcing column made of polyimide material to enhance the overall mechanical strength of the CCS busbar connecting structure, resist external forces that may be received during installation and use, prevent deformation or damage such as bending and breaking of each layer, and maintain the stability of the overall structure.

[0018] The application uses the heat dissipation fins at the top of the upper insulating layer and the bottom of the lower insulating layer to increase the contact area with air, accelerate the heat dissipation when the CCS busbar connecting structure is powered on, effectively reduce the working temperature of the entire CCS busbar connecting structure, avoid affecting the conductivity and insulation performance due to overheating, and prolong the service life. BRIEF DESCRIPTION OF DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0020] Figure 1 is a schematic diagram of the three-dimensional structure of the embodiment.

[0021] Figure 2 is a schematic diagram of the three-dimensional structure of the conductive row one.

[0022] Figure 3 is a schematic diagram of the front view of the embodiment.

[0023] Figure 4 is a schematic diagram of the local front view of the upper insulating layer.

[0024] In the figure, 1 is the upper insulating layer, 101 is the PET insulating film, 2 is the conductive row one, 201 is the busbar, 202 is the single busbar, 203 is the connecting lug, 204 is the copper terminal, 3 is the first intermediate insulating layer, 4 is the conductive row two, 5 is the second intermediate insulating layer, 6 is the FPC flexible circuit board, 7 is the lower insulating layer, 8 is the insulating reinforcing column, and 9 is the heat dissipation fin. DETAILED DESCRIPTION

[0025] The technical solutions of the present application will be described clearly and completely below in conjunction with specific embodiments. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments of the present application, all other embodiments obtained by a person of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0026] Referring to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 , the present application provides a high-voltage CCS busbar connecting piece structure based on a laminated insulation design, comprising an upper insulation layer 1, a conductive busbar 1 2, an intermediate insulation layer 1 3, a conductive busbar 2 4, an intermediate insulation layer 2 5, an FPC flexible circuit board 6 and a lower insulation layer 7. The conductive busbar 1 2 is fixedly connected to the bottom of the upper insulation layer 1. The intermediate insulation layer 1 3 is fixedly connected to the bottom of the conductive busbar 1 2. The conductive busbar 2 4 is fixedly connected to the bottom of the intermediate insulation layer 1 3. The intermediate insulation layer 2 5 is fixedly connected to the bottom of the conductive busbar 2 4. The FPC flexible circuit board 6 is fixedly connected to the bottom of the intermediate insulation layer 2 5. The lower insulation layer 7 is fixedly connected to the bottom of the FPC flexible circuit board 6.

[0027] In the present embodiment, the conductive busbar 1 2 and the conductive busbar 2 4 are the same in structure and size. The conductive busbar 1 2 and the conductive busbar 2 4 are both made of high-purity oxygen-free copper material, and the thickness is 3-5 mm. Since high-purity oxygen-free copper has excellent electrical conductivity, oxidation resistance and corrosion resistance, it can not only reduce the loss in the process of current transmission, but also improve the service life of the conductive busbar 1 2 and the conductive busbar 2 4. The conductive busbar 1 2 and the conductive busbar 2 4 both comprise a busbar 201, a plurality of single busbars 202, two connecting ears 203 and two copper terminals 204. The plurality of single busbars 202 are fixedly installed on the busbar 201 and are evenly arranged in two columns. The two connecting ears 203 are fixedly installed at both ends of the busbar 201. The two copper terminals 204 are fixedly embedded in the corresponding connecting ears 203. The busbar 201 and the two connecting ears 203 are integrally formed. The design of the copper terminals 204 is used to connect with the battery cell or other components, which can improve the strength and conductivity of the connecting part and ensure stable and reliable current transmission.

[0028] In the embodiment, the upper insulation layer 1, the intermediate insulation layer one 3, the intermediate insulation layer two 5 and the lower insulation layer 7 have the same structure, and are all formed by stacking 3-6 layers of PET insulation films 101, each layer of PET insulation film 101 has a thickness of 0.2-0.3 mm, and the surface of the PET insulation film 101 is sprayed with a nanometer-level aluminum oxide coating with a thickness of 50-100 nm. The laminated insulation structure formed by stacking multiple layers of PET insulation films 101 can greatly improve the insulation performance of the CCS busbar connecting piece, increase the insulation distance and the creepage distance, and effectively prevent insulation breakdown. By using the nanometer-level aluminum oxide coating, the insulation strength is high and the heat conduction performance is good, which can further improve the insulation effect and facilitate heat dissipation, thereby providing a solid insulation guarantee for safe operation of the equipment.

[0029] In the embodiment, the bottom of the upper insulation layer 1 is fixedly connected with a plurality of array-distributed insulation reinforcing columns 8, the bottom ends of the insulation reinforcing columns 8 sequentially penetrate the conductive row one 2, the intermediate insulation layer one 3, the conductive row two 4, the intermediate insulation layer two 5 and the FPC flexible circuit board 6, and the bottom ends of the insulation reinforcing columns 8 are fixedly connected with the top of the lower insulation layer 7. The insulation reinforcing columns 8 are made of polyimide material. The design of the insulation reinforcing columns 8 can improve the mechanical strength of the CCS busbar connecting piece as a whole, improve the high-voltage resistance, and prevent bending, breaking and other damages during installation and use.

[0030] In the embodiment, the top surface of the upper insulation layer 1 and the bottom surface of the lower insulation layer 7 are both fixedly connected with a plurality of uniformly arranged heat dissipation fins 9. The design of the heat dissipation fins 9 can enhance the heat dissipation area of the CCS busbar connecting piece, improve the heat dissipation efficiency, and reduce the working temperature of the CCS busbar connecting piece.

[0031] In the embodiment, the FPC flexible circuit board 6 is fixedly connected with a temperature sensor and a voltage acquisition terminal. The temperature sensor is a negative temperature coefficient thermistor, which has the characteristics of high sensitivity and fast response speed, and can accurately and timely monitor the battery temperature. The voltage acquisition terminal is made of elastic copper sheet, which can ensure good contact performance, and has excellent conductivity and corrosion resistance.

[0032] In the embodiment, the upper insulation layer 1, the conductive row one 2, the intermediate insulation layer one 3, the conductive row two 4, the intermediate insulation layer two 5, the FPC flexible circuit board 6 and the lower insulation layer 7 are sequentially fixed by high-temperature-resistant adhesive from top to bottom. By using high-temperature-resistant adhesive, the connection between the layers is firm, and the stability and reliability of the overall structure of the CCS busbar connecting piece are improved. The high-temperature-resistant adhesive can ensure the bonding effect in a high-temperature environment, and ensure the long-term stable operation of the CCS busbar connecting piece under complex working conditions.

[0033] Through the above structure, the high-voltage CCS busbar connecting piece structure based on the laminated insulation design provided by the application, in use, during the electric energy transmission process, the conductive row one 2 and the conductive row two 4 as the core conductive components, by virtue of the excellent conductive performance of high-purity oxygen-free copper, undertake the transmission task of current, the current flows in from the copper terminal 204 at one end, is conducted to the bus bar 201 through the connecting lug 203, is distributed to a plurality of single bus bars 202 through the bus bar 201, and finally flows out from the copper terminal 204 at the other end, completing the current transmission between the battery cell or other components; the heat generated during the current transmission process can increase the contact area with air through the heat dissipation fins 9 at the top of the upper insulation layer 1 and the bottom of the lower insulation layer 7, accelerate the dissipation of heat, thereby reducing the working temperature of the entire CCS busbar connecting piece, avoiding the influence of overheating on the conductive performance and insulation performance, and prolonging the service life; by designing the upper insulation layer 1, the intermediate insulation layer one 3, the intermediate insulation layer two 5 and the lower insulation layer 7 to adopt the laminated design of the multilayer PET insulation film 101, by virtue of the insulation characteristics of the PET insulation film 101 itself and the sufficient insulation distance and creepage distance formed by the multilayer stacking, the abnormal conduction of current between different conductive components or with external structures can be effectively blocked, and insulation breakdown can be effectively prevented, thereby providing a reliable insulation barrier for the entire CCS busbar connecting piece structure, and meeting the high-voltage use requirement; by adopting the insulation reinforcing column 8 made of polyimide material, the overall mechanical strength of the CCS busbar connecting piece structure can be enhanced, external forces that may be received during installation and use can be resisted, deformation or damage such as bending and breaking of each layer can be prevented, and the stability of the overall structure can be maintained.

[0034] The high-voltage CCS busbar connecting piece structure based on the laminated insulation design provided by the application is described in detail above. The principles and implementation modes of the application are described by applying specific embodiments, and the above embodiment descriptions are only used to help understand the method of the application and its core idea. It should be noted that, for ordinary skilled persons in the technical field, without departing from the principles of the application, the application can be improved and modified in several ways, and these improvements and modifications also fall within the protection scope of the claims of the application.

Claims

1. A high-voltage withstand CCS busbar connector structure based on laminated insulation design, characterized in that, The system includes an upper insulating layer (1), a first conductive busbar (2), a first intermediate insulating layer (3), a second conductive busbar (4), a second intermediate insulating layer (5), an FPC flexible circuit board (6), and a lower insulating layer (7). The first conductive busbar (2) is fixedly connected to the bottom of the upper insulating layer (1), the first intermediate insulating layer (3) is fixedly connected to the bottom of the first conductive busbar (2), the second conductive busbar (4) is fixedly connected to the bottom of the first intermediate insulating layer (3), the second intermediate insulating layer (5) is fixedly connected to the bottom of the second conductive busbar (4), the FPC flexible circuit board (6) is fixedly connected to the bottom of the second intermediate insulating layer (5), and the lower insulating layer (7) is fixedly connected to the bottom of the FPC flexible circuit board (6).

2. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: The conductive busbar 1 (2) and the conductive busbar 2 (4) have the same structural dimensions. Both the conductive busbar 1 (2) and the conductive busbar 2 (4) are made of high-purity oxygen-free copper material with a thickness of 3-5mm.

3. The high-voltage CCS busbar connector structure based on laminated insulation design according to claim 2, characterized in that: Both the first conductive bus (2) and the second conductive bus (4) include a busbar (201), multiple individual busbars (202), two connecting lugs (203) and two copper terminals (204). The multiple individual busbars (202) are fixedly installed on the busbar (201) and arranged in two even rows. The two connecting lugs (203) are respectively fixedly installed at both ends of the busbar (201), and the two copper terminals (204) are respectively fixedly embedded in the corresponding connecting lugs (203).

4. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 3, characterized in that: The busbar (201) and the two connecting ears (203) are integrally formed.

5. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: The upper insulating layer (1), the first intermediate insulating layer (3), the second intermediate insulating layer (5) and the lower insulating layer (7) have the same structure. They are all made up of 3-6 layers of PET insulating film (101) stacked together, and the thickness of each layer of PET insulating film (101) is 0.2-0.3mm.

6. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: The bottom of the upper insulating layer (1) is fixedly connected to a plurality of insulating reinforcing columns (8) arranged in an array. The bottom end of the insulating reinforcing column (8) passes through the first conductive busbar (2), the first intermediate insulating layer (3), the second conductive busbar (4), the second intermediate insulating layer (5) and the FPC flexible circuit board (6) in sequence, and the bottom end of the insulating reinforcing column (8) is fixedly connected to the top of the lower insulating layer (7).

7. The high-voltage CCS busbar connector structure based on laminated insulation design according to claim 6, characterized in that: The insulating reinforcing column (8) is made of polyimide.

8. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: The top surface of the upper insulating layer (1) and the bottom surface of the lower insulating layer (7) are both fixedly connected with a plurality of heat dissipation fins (9) arranged in a uniform manner.

9. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: A temperature sensor and a voltage acquisition terminal are fixedly connected to the FPC flexible circuit board (6). The temperature sensor is a negative temperature coefficient thermistor, and the voltage acquisition terminal is made of elastic copper sheet.

10. The high-voltage withstand CCS busbar connector structure based on laminated insulation design according to claim 1, characterized in that: The upper insulating layer (1), conductive busbar one (2), intermediate insulating layer one (3), conductive busbar two (4), intermediate insulating layer two (5), FPC flexible circuit board (6) and lower insulating layer (7) are bonded and fixed from top to bottom with high temperature resistant adhesive.

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