A high-voltage fast-charging busbar for a new energy vehicle

Abstract

The utility model discloses a high pressure fast -charging female row for new energy automobile. The female row includes metal conductor and the insulating layer of cladding metal conductor surface, the insulating layer material is one or more of nylon 12, modified nylon 12. Can solve with temperature promotion, and the problem of the peeling of insulating layer caused by the insufficient adhesion between insulating layer and conductor, improves the heat resistance of insulating layer material.

Description

Technical Field

[0001] This utility model relates to a high-voltage fast charging busbar for new energy vehicles, belonging to the field of new energy vehicle components. Background Technology

[0002] With the popularization of new energy vehicles and consumers' demand for faster charging, fast charging technology has become the mainstream charging technology to further shorten charging time.

[0003] Traditional electrical wires have good bending performance due to their small conductor area, relatively thick insulation layer, and complete conductor coverage. However, in new energy vehicles, with the increase in current, the conductor cross-sectional area is several to tens of times larger than that of traditional wires. The insulation layer is thinner and requires complex bending and forming processes. Due to insufficient adhesion between the insulation layer and the conductor, there is a risk of failure such as insulation layer detachment.

[0004] As the charging power of new energy vehicles increases, the current carried by the corresponding busbars will further increase, generating more heat. This heat accumulation raises the temperature of the conductors and surface insulation materials. When this temperature rises to a certain level, such as reaching the material's heat distortion temperature, it may lead to insulation failure. Improving the heat resistance of the insulation material can further increase the current carrying capacity without increasing the conductor cross-sectional area, thereby increasing the rechargeable power of the busbar and improving charging speed and efficiency. Traditional wire harness insulation materials such as PVC and PE have excellent insulation properties, but their heat resistance is poor, and their heat distortion temperature is low, which is no longer sufficient for current high-voltage fast charging technology.

[0005] Therefore, with the increase in charging power, how to simply and efficiently solve the problem of insulation layer detachment caused by insufficient adhesion between the insulation layer and the conductor is a technical problem that urgently needs to be solved in the field. Utility Model Content

[0006] To address the aforementioned problems in the existing technology, this utility model proposes a high-voltage fast-charging busbar for new energy vehicles, which can solve the problem of insulation layer detachment caused by insufficient adhesion between the insulation layer and the conductor as the temperature rises, and improve the heat resistance of the insulation layer material.

[0007] To achieve the above objectives, the technical solution of this utility model is as follows:

[0008] A high-voltage fast-charging busbar for new energy vehicles includes a metal conductor and an insulating layer covering the surface of the metal conductor;

[0009] The insulating layer material is one or more of nylon 12 (PA12) and modified nylon 12 (modified PA12).

[0010] In one embodiment, the insulating layer material has a voltage rating of 800V and a maximum charging power of 400kW.

[0011] Preferably, the insulating layer material has a melting point ≥178℃;

[0012] Preferably, the insulation layer material has a heat distortion temperature ≥115℃ under a standard pressure of 0.45 MPa;

[0013] Preferably, the insulating layer material has a relative tracking index (CTI) of 600V;

[0014] Preferably, the insulating layer material has a surface resistivity ≥ 10. 14 Ω;

[0015] In one embodiment, the modified nylon 12 is a product formed by changing the physical properties of nylon 12 raw material, such as reinforced nylon, toughened nylon, wear-resistant nylon, flame-retardant nylon, conductive nylon, etc.; in a specific example, the modified nylon 12 can be one or more of Wanhua WANAMIDL2001T, Wanhua L2002T, Wanhua L2030P, Wanhua L2040P, Wanhua L2050PY, etc.

[0016] In one embodiment, the insulating layer is uniformly wrapped around the surface of the metal conductor and has a thickness ranging from 0.6 to 0.8 mm, for example, it can be a range of 0.6 mm, 0.7 mm, 0.8 mm or any two of these.

[0017] In one embodiment, the metal conductor is made of copper.

[0018] In one embodiment, the metal conductor is a strip structure with the same cross-section;

[0019] Preferably, the cross-sectional area of ​​the metal conductor is in the range of 76-80 mm². 2 For example, it can be 76mm 2 77mm 2 78mm 2 79mm 2 80mm 2 Or the range formed by any two of them;

[0020] In one specific example, the cross-section of the metal conductor is rectangular or other irregularly shaped, preferably rectangular, with a length of 10-25 mm, for example, 10 mm, 12 mm, 15 mm, 18 mm, 20 mm, 22 mm, 25 mm or any combination thereof, and a width of 3.2-7.6 mm, for example, 3.2 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.6 mm or any combination thereof.

[0021] In one embodiment, the surface of the metal conductor has wrinkles, which means that the surface is an uneven design, that is, an irregular surface structure. The surface can be an upward protrusion or a downward depression, which is not particularly required. Preferably, the wrinkles are evenly distributed on the surface of the metal conductor.

[0022] In one specific example, the height of the fold ranges from 0 to 0.5 mm, for example, it can be a range of 0 mm, 0.01 mm, 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm or any two of these ranges, and the width ranges from 0 to 5 mm, for example, it can be a range of 0 mm, 0.01 mm, 0.05 mm, 0.1 mm, 0.5 mm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm or any two of these ranges.

[0023] In one specific example, there is no specific requirement for the number of wrinkles on the surface of the metal conductor, nor is there a specific requirement for the shape of the wrinkles. For example, they can be one or more combinations of triangles, rectangles, circles, wavy shapes, etc.

[0024] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0025] In this invention, the insulating layer is made of PA12-based resin material, especially modified PA12 material, which has excellent insulation, heat resistance, and aging resistance. It maintains good performance during processing such as co-extrusion and bending with metal conductors, especially copper-based conductors, without cracking or whitening. Furthermore, due to the excellent temperature resistance of this resin material, it can carry higher currents within the same cross-sectional area of ​​the metal conductor, thus meeting the fast-charging requirements of new energy vehicles and achieving lightweighting and reduced material costs for the busbar.

[0026] Meanwhile, in a preferred embodiment, the metal conductor adopts a long strip structure with the same cross-section, and the surface area of ​​the conductor is further increased by the pleated design of the conductor surface, thereby increasing the bonding area between the conductor and the insulation layer. This can improve the adhesion between the metal conductor and the insulation layer, further enhance the heat exchange and heat dissipation capacity of the interface, reduce the failure risk caused by detachment, and also increase the reliability of the busbar in the complete processing.

[0027] The busbar designed above can better meet the current 4C and 5C fast charging requirements of 80kWh battery packs, and can better balance the size and cost of the busbar. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the cross-section of the high-voltage fast-charging busbar in Example 1;

[0029] Figure 2 This is a schematic diagram of the cross-section of the high-voltage fast-charging busbar in Example 2;

[0030] Figure 3 This is a schematic diagram of the cross-section of the high-voltage fast-charging busbar in Example 3;

[0031] In the diagram, 1 is a metal conductor, 2 is a fold, and 3 is an insulating layer. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0033] The main analytical methods used in the embodiments and comparative examples of this invention are as follows:

[0034] Melting point: ISO 11357-3-2018;

[0035] Heat distortion temperature (0.45MPa): GBT1634-2004;

[0036] Relative Tracking Index (CTI): GB / T6553-2014;

[0037] Surface resistivity: GBT-1410-2006.

[0038] The embodiments of this utility model are described below with reference to the accompanying drawings.

[0039] Example 1

[0040] In this embodiment, the busbar is a long strip structure with the same cross-section, as shown in the figure below. Figure 1 As shown, it comprises a copper metal conductor (1) and an outer insulating layer (3) made of modified PA12.

[0041] The outer insulating layer (3) has a thickness of 0.7 mm and is uniformly wrapped on the surface of the metal conductor (1).

[0042] The metal conductor (1) is a long strip structure with the same cross-section. Its cross-sectional structure is rectangular, with a width and height of 20 mm and 4 mm respectively, and a cross-sectional area of ​​80 mm². 2 The cross-sectional perimeter is 48mm.

[0043] The modified PA12 material is designated as Wanhua Chemical WANAMIDL2001T, with a melting point of 179℃, a heat distortion temperature (0.45MPa) of 116℃, a relative tracking index (CTI) of 600V, and a surface resistivity of 2.2*10⁻⁶. 15 Ω.

[0044] Under ambient temperature of 23℃, natural convection conditions, a voltage rating of 800V, and a charging power of 400kW (equivalent to a 5C charging rate for an 80kWh battery pack), the surface temperature of the insulation layer, calculated by CAE simulation, reached 108.0℃ after 12 minutes. At this temperature, the insulation material did not exhibit thermal deformation, peeling, or other defects, and its insulation remained intact.

[0045] Example 2

[0046] Based on the busbar structure and dimensions of Example 1, the difference lies in that the surface of its metal conductor (1) is augmented with uniformly distributed folds (2), and its cross-sectional structure is a rectangular + irregularly shaped folded surface, as shown in the figure. Figure 2 As shown, the fold (2) is an arc shape with an arc width of 4.17 mm and a height of 0.4 mm. Compared with the rectangular cross-section of Example 1, the perimeter is increased by 1.75 mm, and its adhesion to the insulation layer and heat dissipation effect are better.

[0047] The modified PA12 material is designated as Wanhua Chemical WANAMIDL2001T, with a melting point of 179℃, a heat distortion temperature (0.45MPa) of 116℃, a relative tracking index (CTI) of 600V, and a surface resistivity of 2.2*10⁻⁶. 15 Ω.

[0048] Under ambient temperature of 23℃, natural convection conditions, a voltage rating of 800V, and a charging power of 400kW (equivalent to a 5C charging rate for an 80kWh battery pack), the surface temperature of the insulation layer, calculated by CAE simulation, reached 106.7℃ after 12 minutes. At this temperature, the insulation material did not exhibit thermal deformation, peeling, or other defects, and its insulation remained excellent.

[0049] Example 3

[0050] In this embodiment, the busbar is a long strip structure with the same cross-section, as shown in the figure below. Figure 3 As shown, it comprises a copper metal conductor (1) and an outer insulating layer (3) made of modified PA12.

[0051] The outer insulating layer (3) has a thickness of 0.7 mm and is uniformly wrapped on the surface of the metal conductor (1).

[0052] The metal conductor (2) is a long strip structure with a rectangular cross-section and an irregularly shaped pleated surface. The width and height, calculated using the rectangular structure excluding the pleats, are 22.07 mm and 4 mm respectively, and its area is 88.28 mm². 2 The perimeter of the rectangle is 52.14 mm.

[0053] The folds (3) are evenly distributed on the surface of the metal conductor. The folds (3) are triangular with a width of 4.28 mm and a height of 0.4 mm. The perimeter of the cross section is 2.35 mm longer than that of the rectangle without the folds.

[0054] The modified PA12 material is designated as Wanhua Chemical WANAMIDL2001T, with a melting point of 179℃, a heat distortion temperature (0.45MPa) of 116℃, a relative tracking index (CTI) of 600V, and a surface resistivity of 2.2*10⁻⁶. 15 Ω.

[0055] Under ambient temperature of 23℃ and natural convection conditions, with a voltage rating of 800V and a charging power of 400kW (equivalent to a 5C charging rate for an 80kWh battery pack), the surface temperature of the insulation layer, calculated by CAE simulation, reached 106.1℃ after 12 minutes. At this temperature, the insulation material did not exhibit thermal deformation, peeling, or other defects, and its insulation remained intact.

[0056] Comparative Example 1

[0057] The comparative example busbar has the same structure as that in Example 3, and its cross-section is as shown below. Figure 3 The only difference is that the material of the outer insulation layer (3) is replaced with modified PA12 and SG-3 type PVC material for cables, which has a melting point of 170℃, a heat distortion temperature (0.45MPa) of 70℃, and a surface resistivity of 1*10. 12 Ω.

[0058] Under ambient temperature of 23℃, natural convection conditions, a voltage rating of 800V, and a charging power of 400kW (equivalent to a 5C charging rate for an 80kWh battery pack), the surface temperature of the insulation layer, calculated by CAE simulation, reached 110.0℃ after 12 minutes. At this temperature, the insulation material began to show localized softening, failing to adequately meet the requirements for busbar operation.

[0059] The applicant declares that this utility model is illustrated through the above embodiments as a busbar for high-voltage fast-charging new energy vehicles, but this utility model is not limited to the above structure and method, that is, it does not mean that this utility model must rely on the above structure and method to be implemented. Those skilled in the art should understand that any improvements to this utility model, or equivalent substitutions of the materials selected in this utility model, fall within the protection and disclosure scope of this utility model.

Claims

1. A high-voltage fast-charging busbar for a new energy vehicle, characterized in that, Includes the metallic conductor and the insulating layer covering the surface of the metallic conductor; The insulating layer is made of either nylon 12 or modified nylon 12. The cross-sectional area of the metal conductor ranges from 76 to 80 mm 2 .

2. The high-voltage fast-charging busbar for a new energy vehicle according to claim 1, characterized in that, The insulating layer material has a voltage rating of 800V and a maximum charging power of 400kW; and / or The insulating layer material has a melting point ≥178℃; and / or The insulation layer material has a heat distortion temperature ≥115℃ under a standard pressure of 0.45 MPa; and / or The insulating layer material has a relative tracking index (CTI) of 600V; and / or The insulating layer material has a surface resistivity ≥ 10 14 Ω. 3.The high-voltage fast-charging busbar for new energy vehicles according to claim 1, characterized in that, The modified nylon 12 is one of Wanhua WANAMIDL2001T, Wanhua L2002T, Wanhua L2030P, Wanhua L2040P, and Wanhua L2050PY.

4. The high-voltage fast-charging busbar for new energy vehicles according to claim 1, characterized in that, The insulating layer is uniformly wrapped around the surface of the metal conductor, with a thickness ranging from 0.6 to 0.8 mm.

5. The high-voltage fast-charging bus bar for new energy vehicles according to claim 1, characterized in that, The metal conductor is made of copper.

6. The high-voltage fast-charging bus bar for a new energy vehicle according to claim 1, characterized in that, The cross-section of the metal conductor is rectangular, with a length of 10-25 mm and a width of 3.2-7.6 mm.

7. The high-voltage fast-charging busbar for new energy vehicles according to claim 1, characterized in that, The surface of the metal conductor has wrinkles.

8. The high-voltage fast-charging bus bar for a new energy vehicle according to claim 7, characterized in that, The wrinkles are evenly distributed on the surface of the metal conductor. 9.The high-voltage fast-charging busbar for new energy vehicles of claim 7, characterized in that, The height of the folds ranges from 0 to 0.5 mm, and the width ranges from 0 to 5 mm.

10. The high-voltage fast-charging bus bar for a new energy vehicle according to claim 8, characterized in that, The shape of the folds is one or more combinations of triangles, rectangles, circles, and waves.

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