A busbar preparation method and capacitor busbar prepared therefrom

Abstract

The present invention discloses a busbar preparation method and a capacitor busbar prepared therefrom, which are used to prepare a busbar whose wiring terminals are perpendicular to a substrate and located in the middle of the substrate; the preparation method comprises: bending a copper plate into a wiring portion and a connecting portion, wherein the wiring portion is the same as a portion of the wiring terminal perpendicular to the substrate; the connecting portion is perpendicular to the wiring portion; at least one accommodating groove matching the connecting portion is provided on the substrate; the connecting portion and the accommodating groove are welded together at the connecting position thereof by laser welding; the present invention provides a busbar preparation method and a capacitor busbar prepared therefrom, which have a simple structure, a reasonable design and are easy to implement, solve the problem of difficulty in assembling the wiring terminals and the busbar substrate, greatly improve the welding production efficiency, and effectively reduce the scrap rate caused by unreliable welding.

Description

Technical Field

[0001] The invention relates to the field of power conversion and control, and in particular to a capacitor busbar for new energy vehicles. Background Art

[0002] At present, the existing capacitor busbars are widely used in new energy vehicles, electronic and electrical equipment, DC power transmission and distribution, electric locomotives, wind energy, solar energy conversion and grid connection and other fields;

[0003] Most of the traditional methods for preparing capacitor busbars are to directly insert the terminal blocks vertically into the holes opened on the busbar substrate, and then fix them by laser welding along the edges of the holes (it should be noted here that laser welding cannot fully fuse the molecules of the mutually perpendicular terminal blocks and the busbar substrate, and the welding is not reliable); the above method has a simple structure and production process, so it is widely used; but the above process has the following defects: the holes for inserting the terminal blocks are opened on the busbar substrate, and the holes will not be smoothly inserted due to machining accuracy errors. If the gap between the terminal blocks and the holes is too large, the molecules cannot be fully fused during welding, resulting in welding failure or poor welding. Reliable, often welders need to adjust the gap size in all directions before welding, which leads to very low welding efficiency and high scrap rate; if the gap between the terminal and the hole is too small, the terminal cannot be inserted and needs to be expanded. The above only considers the hole processing part; you should know that the terminal is also made of sheet metal, and its thickness is usually the original thickness of the sheet metal, and the thickness of the sheet metal is often different, and the hole of the busbar substrate is uniformly stamped after the size design is determined. In this way, when assembling the terminal, some cannot be assembled due to too small size, and some cannot be welded due to too large gap between the two after insertion;

[0004] Therefore, there is still room for further improvement in the existing capacitor busbar preparation process and capacitor busbar. Summary of the invention

[0005] The purpose of the present invention is to solve the existing problems, provide a busbar preparation method and a capacitor busbar prepared therefrom, which has a simple structure, reasonable design and is easy to implement, solves the problem of difficult assembly of the wiring terminal and the busbar substrate, greatly improves the welding production efficiency, and effectively reduces the scrap rate caused by unreliable welding;

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] A busbar preparation method is used to prepare a busbar whose connection terminals are perpendicular to a substrate and located in the middle of the substrate, wherein the busbar comprises a substrate and connection terminals; the preparation method comprises:

[0008] A copper plate is bent into a wiring portion and a connecting portion, wherein the copper plate is a wiring terminal, and the wiring portion is a portion of the wiring terminal perpendicular to the substrate; and the connecting portion is perpendicular to the wiring portion;

[0009] At least one receiving groove matching the connecting portion is provided on the base plate;

[0010] The connecting portion and the containing groove are welded together at the connecting position thereof by laser welding.

[0011] Furthermore, a heat-insulating groove is provided on the accommodating groove, and the heat-insulating groove corresponds to the bending position of the wiring portion and the connecting portion.

[0012] A capacitor busbar comprises: a substrate and a wiring terminal; a receiving groove is provided in the middle of the substrate, and the receiving groove is a closed groove with closed edges; the wiring terminal comprises a wiring portion and a connecting portion connected as one body, and the wiring portion extends vertically relative to the substrate; wherein the connecting portion is embedded in the receiving groove and is welded along the junction of the connecting portion and the receiving groove by laser welding, so that the wiring terminal is fixedly connected to the substrate.

[0013] Furthermore, the accommodating groove on the substrate is also provided with at least one heat-insulating groove, and the heat-insulating groove is correspondingly provided at the bending position of the connecting portion and the wiring portion.

[0014] Furthermore, the shape of the connecting portion is an “I” shape; the shape of the accommodating groove is adapted to the shape of the connecting portion.

[0015] Furthermore, a side of the connecting portion away from the wiring portion is V-shaped or trapezoidal; and the shape of the accommodating groove is adapted to the shape of the connecting portion.

[0016] Furthermore, a side of the connecting portion away from the wiring portion is arc-shaped; and the shape of the accommodating groove is adapted to the shape of the connecting portion.

[0017] Furthermore, the shape of the connecting portion is T-shaped; the shape of the accommodating groove is adapted to the shape of the connecting portion.

[0018] Compared with the prior art, the technical solution of the present invention has the following beneficial effects:

[0019] (1) The busbar preparation method and the capacitor busbar prepared by the present invention have a simple structure, reasonable design and are easy to implement. The connection portion after the terminal is bent is assembled with the receiving groove on the substrate. The connection portion is used as the part connected to the receiving groove. The distance between the connection portion and the receiving groove can be adjusted arbitrarily without being affected by the thickness of the terminal. The problem of difficult assembly and positioning of the terminal and the busbar substrate is effectively solved, the welding production efficiency is greatly improved, and the scrap rate caused by unreliable welding is effectively reduced.

[0020] (2) The present invention also provides a heat-insulating groove, which plays a good role in heat insulation. The welding position ends at the position of the heat-insulating groove, so that the heat of laser welding is not easily transferred to the wiring part, that is, the heat-affected zone generated by laser welding will not affect the wiring part. The specific reason is that during the welding process, the heat generated by laser welding is transferred to the periphery (that is, the heat-affected zone is generated); the existing wiring terminals are directly inserted into the substrate, and after welding, the heat-affected zone is left on the wiring part for 5-10 cm; it should be noted that when the capacitor busbar is actually used, it needs to be insulated and packaged in a box body, leaving only the wiring part exposed to connect or connect to the power supply component. However, during packaging, the range of the heat-affected zone is too large and cannot be completely covered by the insulator, leaving part of the heat-affected zone outside. The heat-affected zone reserved outside has poor oxidation resistance and stability, and is damaged after a period of use, which is prone to short circuit and cannot meet the actual use requirements.

[0021] (3) The connection part of the present invention is in the shape of an “I” character, which is firmly welded, extends the welding position, and improves the tensile strength of the connection part;

[0022] (4) The shape of the connecting portion of the present invention is V-shaped or trapezoidal, and the inclined surface of the V-shaped or trapezoidal shape is used to achieve the effect of rapid guiding and positioning, making assembly easier;

[0023] (5) The shape of the connecting portion of the present invention is arc-shaped. The arc-shaped connecting portion not only plays a guiding and positioning assembly effect, but also can adjust the angle along the arc according to actual conditions, which is easier to meet the actual assembly positioning requirements and is more convenient to use. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0025] Figure 1 It is a schematic diagram of the three-dimensional exploded structure of the capacitor busbar of the present invention;

[0026] Figure 2 It is a schematic diagram of the three-dimensional structure of the capacitor busbar of the present invention;

[0027] Figure 3 This is a schematic diagram of the three-dimensional structure of the capacitor busbar according to the first embodiment of the present invention;

[0028] Figure 4 Schematic diagram of the three-dimensional structure of the capacitor busbar according to the second embodiment of the present invention Figure 1 ;

[0029] Figure 5 Schematic diagram of the three-dimensional structure of the capacitor busbar according to the second embodiment of the present invention Figure 2 ;

[0030] Figure 6 This is a schematic diagram of the three-dimensional structure of the capacitor busbar according to the third embodiment of the present invention;

[0031] Figure 7 It is a schematic diagram of the three-dimensional structure of the capacitor busbar according to the fourth embodiment of the present invention. DETAILED DESCRIPTION

[0032] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention clearer and more understandable, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0033] like Figure 1 , 2 As shown, a capacitor busbar described in the present invention is widely used in new energy vehicles, power supply equipment, etc. The present invention takes a capacitor busbar used in the field of new energy vehicles as an example;

[0034] The capacitor busbar 1 includes the following main parts: a substrate 2 and a wiring terminal 3;

[0035] The substrate 2 has a receiving groove 20 in the middle thereof, and the receiving groove 20 is a closed groove with closed edges. It should be noted that the receiving groove 20 is provided in the middle of the substrate 2, and the middle here specifically refers to: the part not at the edge of the substrate 2 is the middle of the substrate 2, that is, except for the edge of the substrate 2, it is located at any position in the substrate 2;

[0036] The wiring terminal 3 includes a wiring portion 31 and a connecting portion 32 connected as one body, wherein the wiring portion 31 extends perpendicularly relative to the substrate 2; of course, the wiring portion 31 and the connecting portion 32 may also be arranged at a certain angle (the present invention takes the angle of 90° as an example, that is, the wiring portion 31 and the connecting portion 32 are arranged perpendicularly to each other);

[0037] The connecting portion 32 is embedded in the receiving groove 20 , and is welded along the joint between the connecting portion 32 and the receiving groove 20 by laser welding, so that the connecting terminal 3 is fixedly connected to the substrate 2 .

[0038] More specifically, in order to reduce the influence of the heat-affected zone 4 on the wiring portion 31, the accommodating groove 20 on the substrate 2 is further provided with at least one heat-insulating groove 5, and the heat-insulating groove 5 is correspondingly provided at the bending position of the connecting portion 32 and the wiring portion 31 (preferably, the present invention takes two heat-insulating grooves 5 as an example, which are symmetrically arranged at the bending position of the connecting portion 32 and the wiring portion 31).

[0039] Specific implementation method, the specific method of preparing the capacitor busbar 1 is as follows:

[0040] A method for manufacturing a bus bar, which is used to manufacture a bus bar with a terminal 3 perpendicular to a substrate 2 and located in the middle of the substrate 2. The bus bar includes a substrate and a terminal (the middle part has been specifically described above and will not be repeated here); the manufacturing method includes:

[0041] Select a copper plate as the terminal 3, and bend a copper plate into a connection part 31 and a connecting part 32. The connection part 31 is the part of the terminal 3 perpendicular to the substrate 2; the connecting part 32 is perpendicular to the connection part 31;

[0042] Select a copper plate as the substrate 2, and open at least one receiving groove 20 matching the connecting part 32 in the middle of the substrate 2 through a stamping process;

[0043] Finally, laser weld the connecting part 32 and the receiving groove 20 together at their connection positions to complete the production of the capacitor bus bar 1;

[0044] To prevent the influence of the heat-affected zone 4 on the connection part 31, a heat insulation groove 5 can also be opened on the receiving groove 20, and the heat insulation groove 5 corresponds to the bending position of the connection part 31 and the connecting part 32.

[0045] Example 1, as Figure 3 shown, the present invention takes the terminal 3 with the connecting part 32 in the shape of a "工"

[0046] character as an example;

[0047] Select a copper plate as the terminal 3, and bend a copper plate into a connection part 31 and a connecting part 32A. The connecting part 32A is formed by stamping through a stamping process so that the shape of the connecting part 32 is in the shape of a "工" character.

[0048] Select a copper plate as the substrate 2, and open at least one receiving groove 20 matching the connecting part 32A in the middle of the substrate 2. The position where the receiving groove 20 is opened is selected according to actual needs, and the shape of the receiving groove 20 is the same as the shape of the connecting part 32A, and its groove diameter is not less than the outer dimension of the connecting part 32A;

[0049] Embed the connecting part 32 into the receiving groove 20 formed by the substrate 2;

[0050] Finally, laser weld the connecting part 32A and the receiving groove 20 together at their connection positions to complete the production of the capacitor bus bar 1; the shape of the connecting part 32A of the present invention is in the shape of a "工" character, which extends the welding position, is more firm after welding, and also improves the tensile strength of the connecting part 32A;

[0051] In order to prevent the heat-affected zone 4 from affecting the connection portion 31 , two heat-insulating grooves 5 may be provided on the receiving groove 20 , and the two heat-insulating grooves 5 correspond to the two sides of the connection portion where the connection portion 31 and the connection portion 32A are bent.

[0052] Embodiment 2, as Figure 4 , 5 As shown, in this embodiment, the side of the connecting portion 32B away from the wiring portion 31 is V-shaped or trapezoidal; the shape of the accommodating groove 20 is adapted to the shape of the connecting portion 32B; the same parts as those in the embodiment 1 are not repeated in this embodiment, only the cross-sectional shape of the connecting portion 32B is different, and the V-shaped or trapezoidal inclined surface is used to achieve the effect of rapid guiding and positioning, making assembly easier;

[0053] Embodiment three, as Figure 6 As shown, in this embodiment, the side of the connecting portion 32C away from the wiring portion is arc-shaped; the shape of the accommodating groove 20 is adapted to the shape of the connecting portion 32C; the same parts as those of embodiments 1 and 2 are not repeated in this embodiment, and only the cross-sectional shape of the connecting portion 32C is different. The arc-shaped connecting portion 32C not only plays a guiding and positioning assembly effect, but also can be adjusted along its arc shape according to actual conditions, which is easier to meet actual assembly and positioning requirements and is more convenient to use;

[0054] Embodiment 4: The above only uses three embodiments to illustrate the shape of the connecting portion 32. Of course, other shapes are also possible, for example: Figure 7 As shown, the shape of the connection portion 32 is square, T-shaped, polygonal, etc., as long as it can achieve connection.

[0055] The capacitor busbar provided by the present invention has a simple structure, reasonable design and is easy to implement. The connection part after the terminal is bent is assembled with the receiving groove on the substrate. The connection part is used as the part connected to the receiving groove. The distance between the connection part and the receiving groove can be adjusted arbitrarily without being affected by the thickness of the terminal. The problem of difficult assembly and positioning of the terminal and the busbar substrate is effectively solved, the welding production efficiency is greatly improved, and the scrap rate caused by unreliable welding is effectively reduced. The present invention also provides a heat insulation groove, which plays a good heat insulation role. The welding position ends at the heat insulation groove position, so that the heat of laser welding is not easily conducted to the wiring part, that is, the heat affected zone generated by laser welding will not affect the wiring part. The specific reason is: during the welding process, the heat generated by laser welding is conducted to the periphery (that is, a heat affected zone is generated); the existing terminal is directly inserted into the substrate, and after welding, the heat affected zone remains on the wiring part for 5-10 mm; it should be known that , when the capacitor busbar is actually used, it needs to be insulated and packaged in a box body, leaving only the wiring part exposed to connect or connect to the power supply component. However, during packaging, the heat-affected zone is too large to be completely covered by the insulator, and part of the heat-affected zone is left outside. The heat-affected zone reserved outside has poor oxidation resistance and stability, and is damaged after a period of use. It is easy to cause corrosion and short circuit, and cannot meet the actual use requirements; the shape of the connecting part of the present invention is in the shape of an "I" character, and its welding is firm, the welding position is extended, and the tensile strength of the connecting part is improved; the shape of the connecting part of the present invention is V-shaped or trapezoidal, and the inclined surface of the V-shaped or trapezoidal shape is used to achieve the effect of rapid guiding and positioning, making assembly easier; the shape of the connecting part of the present invention is arc-shaped, and the arc-shaped connecting part not only plays the assembly effect of guiding and positioning, but also can adjust the angle along its arc according to actual conditions, which is easier to meet the actual assembly and positioning requirements and more convenient to use;

[0056] The above description shows and describes the preferred embodiments of the present invention. As mentioned above, it should be understood that the present invention is not limited to the form disclosed herein, and should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be modified within the scope of the invention concept described herein through the above teachings or the technology or knowledge of the relevant field. The changes and modifications made by those skilled in the art do not depart from the spirit and scope of the present invention, and should be within the scope of protection of the claims attached to the present invention.

Claims

1. A method for preparing a busbar, which is used to prepare a busbar whose connecting terminals are perpendicular to a substrate and located in the middle of the substrate, wherein the busbar comprises a substrate and connecting terminals, and is characterized in that: The preparation method comprises: A copper plate is bent into a wiring portion and a connecting portion, wherein the copper plate is a wiring terminal, and the wiring portion is a portion of the wiring terminal perpendicular to the substrate; and the connecting portion is perpendicular to the wiring portion; At least one receiving groove matching the connecting portion is provided on the substrate; the connecting portion and the receiving groove are welded together at the connecting position thereof by laser welding; The shape of the connecting portion is in the shape of an "I" character; the shape of the receiving groove is adapted to the shape of the connecting portion; The receiving groove on the substrate is also provided with two heat-insulating grooves, and the two heat-insulating grooves are symmetrically arranged on both sides of the connecting portion at the bending position of the wiring portion and the connecting portion.

2. A capacitor busbar, prepared by the busbar preparation method according to claim 1, characterized in that: the capacitor busbar comprises: A substrate and a terminal block; a receiving groove is provided in the middle of the substrate, and the receiving groove is a closed groove with closed edges; the terminal block includes a wiring portion and a connecting portion connected as one body, and the wiring portion extends vertically relative to the substrate; wherein the connecting portion is embedded in the receiving groove, and is welded along the junction of the connecting portion and the receiving groove by laser welding, so that the terminal block is fixedly connected to the substrate; The receiving groove on the substrate is also provided with two heat-insulating grooves, and the two heat-insulating grooves are symmetrically arranged on both sides of the connection part at the bending position of the wiring part and the connection part; The shape of the connecting portion is in the shape of an "I" character; the shape of the accommodating groove is adapted to the shape of the connecting portion.

3. A capacitor busbar as claimed in claim 2, characterized in that: The side of the connecting portion away from the wiring portion is V-shaped or trapezoidal: the shape of the accommodating groove is adapted to the shape of the connecting portion.

4. A capacitor busbar as claimed in claim 2, characterized in that: The side of the connecting portion away from the wiring portion is arc-shaped; the shape of the accommodating groove is adapted to the shape of the connecting portion.

5. A capacitor busbar as claimed in claim 2, characterized in that: The shape of the connecting portion is T-shaped; the shape of the accommodating groove is matched with the shape of the connecting portion.

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