A novel combined insulating busbar structure and its processing method

Abstract

A novel combined insulating busbar structure includes at least two conductive plates arranged at intervals, two insulating films respectively arranged on both sides of the conductive plates arranged at intervals, and at least one insulating structure arranged between the conductive plates. The conductive plates are provided with at least one corresponding bending portion, an L-shaped groove close to the bending portion is formed between two adjacent conductive plates and the insulating film, and two strip grooves are arranged at both ends of the L-shaped groove and connected to the L-shaped groove. The insulating structure includes two insulating plugs respectively embedded in the strip grooves, and a potting glue filled in the L-shaped groove. The novel combined insulating busbar structure reduces the R&D and production costs by combining the insulating plugs with the potting glue insulation, has high working efficiency and is suitable for large-scale industrial production.

Description

Technical Field

[0001] The invention belongs to the technical field of composite busbars, in particular to a novel combined insulating busbar structure. Background Art

[0002] At present, the busbar structure in the composite busbar industry is generally constructed by vertical stacking. In order to further increase the number of busbar plates, research has begun on the direction of horizontal stacking of busbar plates.

[0003] The main insulation method in the existing busbar horizontal stacking method is to use PET film to insulate the two sides of the plate, and to use insulating plugs to insulate between the plates, so as to ensure the insulation performance of the busbar under high voltage. However, in the actual use of the busbar, the plates need to be bent multiple times, generally as follows Figure 1 As shown, the product has a special structure and has high insulation requirements. There is a gap between the two parallel plates through the bending structure. The existing insulation method is to use L-shaped insulating plugs to fill and cover the insulating film. Although it meets the insulation performance requirements under high voltage at the bend, the mold cost for manufacturing the filled insulating plugs and covering the surface insulating film is also very expensive. At the same time, in order to increase the fit between the insulating plugs and the outer walls of the plates on both sides, the bending stress properties of the insulating plugs also need to be consistent with the bending stress properties of the plates, or the insulating plugs need to be refined again after being bent. The production efficiency is low and it is not suitable for mass production. Summary of the invention

[0004] In view of this, the present invention provides a novel combined insulating busbar structure to solve the above problems.

[0005] A novel combined insulated busbar structure includes at least two conductive plates arranged at intervals, two insulating films respectively arranged on both sides of the conductive plates arranged at intervals, and at least one insulating structure arranged between the conductive plates. The conductive plates are provided with at least one corresponding bending portion, an L-shaped groove close to the bending portion is formed between two adjacent conductive plates and the insulating film, and two strip grooves are arranged at both ends of the L-shaped groove and connected to the L-shaped groove. The insulating structure includes two insulating plugs respectively embedded in the strip grooves, and a potting glue filled in the L-shaped groove.

[0006] Furthermore, the circumferential edge of the insulating film protrudes beyond the outermost circumferential edge of the conductive plates arranged at intervals.

[0007] Furthermore, a potting port communicating with the L-shaped groove is provided on one side of the insulating film close to the bending portion.

[0008] Furthermore, the insulating plug is matched with the strip groove structure and two sides of the insulating plug fit tightly against the outer wall of the conductive plate.

[0009] Furthermore, a limiting structure is provided between the insulating plug and the conductive plate.

[0010] Furthermore, the limiting structure includes two positioning grooves arranged on the outer wall of the conductive plate located in the strip groove, and two positioning protrusions respectively arranged on both sides of the insulating plug and correspondingly inserted into the positioning grooves.

[0011] Furthermore, the limiting structure includes two arc-shaped concave surfaces arranged on the outer wall of the conductive plate located in the L-shaped groove, and two arc-shaped convex surfaces respectively arranged on both sides of the insulating plug and correspondingly fitting the arc-shaped concave surfaces.

[0012] Furthermore, one end of the insulating plug away from the L-shaped groove is flush with one side surface of the conductive plate.

[0013] Furthermore, the length of the insulating plug is 30%-40% of the length of the conductive plate.

[0014] Furthermore, the processing steps of the novel combined insulating busbar structure are as follows:

[0015] A. Cutting and blanking: stamping the copper material into two rectangular conductive plates, cutting and processing the insulating plugs according to the structure of the outer walls on both sides of the conductive plates. The length of the insulating plugs is 40% of the length of the conductive plates.

[0016] B. Level and arrange. Lay the conductive plates flatly at intervals in the width direction and embed two insulating plugs into the two ends of the gap formed by the conductive plates, so that the two sides of the insulating plugs are tightly attached to the outer wall of the conductive plates and the ends of the insulating plugs are flush with the surface of one side of the conductive plates.

[0017] C. Pressing and bending: placing two insulating films on both sides of the flattened conductive plate and the insulating plug respectively, and combining them into an integral module by hot pressing. By clamping the two ends of the overall module in the length direction, the clamping length of both ends is equal to the length of the insulating plug, and the conductive plate is bent along the midline of the length of the conductive plate.

[0018] D. Opening holes for potting: at least one potting opening is opened on the insulating film between the two insulating plugs, and the potting glue is filled into the L-shaped groove through the potting opening.

[0019] Compared with the prior art, a novel combined insulating busbar structure provided by the present invention replaces the original L-shaped insulating plug insulation method by combining an insulating plug with glue-filled insulation, thereby ensuring the support of the busbar combination and improving the fit between the insulating structure and the outer wall of the spaced conductive plate, preventing the insulating film on the outside of the conductive plate from being subjected to stress damage, further improving the insulation performance of the busbar, and simplifying the processing method. There is no need to bend the insulating plug, thereby reducing the processing difficulty and making the processing method highly versatile, suitable for insulating structures in various situations, and no need to develop molds for manufacturing different types of insulating plugs and covering the surface insulating film, thereby reducing the R&D and production costs, having high work efficiency and being suitable for large-scale industrial production. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the busbar insulation structure in the prior art.

[0021] Figure 2 A schematic diagram of a novel combined insulated busbar structure provided by the present invention.

[0022] Figure 3 for Figure 2 Schematic diagram of the explosion structure of the new combined insulated busbar structure.

[0023] Figure 4 This is a schematic diagram of the limiting structure of the new combined insulating busbar structure in Example 1.

[0024] Figure 5 This is a schematic diagram of the limiting structure of the new combined insulating busbar structure in Example 2. DETAILED DESCRIPTION

[0025] The specific embodiments of the present invention are further described in detail below. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the protection scope of the present invention.

[0026] See also Figures 2 to 4 , which is a schematic diagram of a novel combined insulated busbar structure provided by the present invention. A novel combined insulated busbar structure, which includes at least two conductive plates 10 arranged at intervals, two insulating films 20 respectively arranged on both sides of the conductive plates 10 arranged at intervals, and at least one insulating structure 30 arranged between the conductive plates 10. It can be imagined that the novel combined insulated busbar structure also includes other functional components and specific structures, such as electrical connection components, connection terminals, etc., which are all well-known technologies to those skilled in the art, so they will not be described in detail one by one here.

[0027] At least one corresponding bending portion is provided on the conductive plate 10, and an L-shaped groove 11 close to the bending portion is formed between two adjacent conductive plates 10 and the insulating film 20, as well as two strip grooves 12 arranged at both ends of the L-shaped groove 11 and connected to the L-shaped groove 11. In this embodiment, the conductive plate 10 is bent along the center line of its length direction and has only one bending portion, that is, the cross section of the conductive plate 10 is L-shaped. It is conceivable that more than two bending portions may be provided on the conductive plate 10 and the cross section of the conductive plate 10 may be U-shaped or Z-shaped, etc., which are all reasonable extensions of this embodiment.

[0028] In this embodiment, the insulating film 20 is made of PET film. The circumferential edge of the insulating film 20 protrudes from the outermost circumferential edge of the conductive plates 10 arranged at intervals, and the insulating film 20 ensures the insulation of both sides of the conductive plates 10.

[0029] The insulating structure 30 includes two insulating plugs 31 respectively embedded in the strip grooves 12, and a potting glue 32 filled in the L-shaped groove 11. The insulating plug 31 matches the structure of the strip groove 12, and the two sides of the insulating plug 31 fit tightly against the outer wall of the conductive plate 10, and the end of the insulating plug 31 away from the L-shaped groove 11 is flush with the surface of one side of the conductive plate 10. The insulating plug 31 is strip-shaped and the length of the insulating plug 31 is 30%-40% of the length of the conductive plate 10. The insulating plug 31 is used to achieve insulation of the strip grooves 12 between adjacent conductive plates 10. The strip-shaped insulating plug 31 is easy to process, which is conducive to the insulating plug 31 fitting the outer wall of the conductive plate 10 on both sides of the strip groove 12. In order to achieve axial limitation of the insulating plug 31 in the strip groove 12, at least one side protrusion 34 can be provided at one end of the insulating plug 31 close to the L-shaped groove 11, and an arc-shaped protrusion 35 is provided at one end of the strip groove 12 close to the L-shaped groove 11, and the side protrusion 34 abuts against the arc-shaped protrusion 35.

[0030] A limiting structure 33 is provided between the insulating plug 31 and the conductive plate 10. The limiting structure 33 includes two positioning grooves 331 provided on the outer wall of the conductive plate 10 located in the L-shaped groove 11, and two positioning protrusions 332 provided on both sides of the insulating plug 31 and correspondingly inserted into the positioning grooves 331. The positioning protrusions 332 on both sides of the insulating plug 31 are inserted into the positioning grooves 331 on the outer wall of the conductive plate 10, so that the insulating plug 31 is initially positioned in the conductive plate 10, and the conductive plates 10 adjacent to each other on both sides are connected to form support at both ends of the conductive plate 10, and the axial limiting of the side protrusions 34 and the arc-shaped protrusions 35 is combined, so that the connection between the insulating plug 31 and the conductive plate 10 is reliable and the structure is stable, so as to facilitate the pressing of the insulating film 20 on both sides of the conductive plate 10 and the insulating plug 31.

[0031] A potting port 21 connected to the L-shaped groove 11 is provided on one side of the insulating film 20 close to the bending portion, and a potting glue 32 is filled into the L-shaped groove 11 through the potting port 21. After the potting glue 32 is solidified, the insulation of the conductive plate 10 in the L-shaped groove 11 is realized. The insulating structure 30 formed by the potting method is more consistent with the structure of the L-shaped groove 11, and the end of the insulating plug 31 is bonded to form an internal support of the insulating plug 31, so that the insulation is better, and the insulating film 20 on the outside of the conductive plate 10 will not be damaged by stress, so that the insulating film 20 has a longer service life and a more durable insulation performance.

[0032] The processing steps of the novel combined insulating busbar structure are as follows:

[0033] A. Cutting: stamping the copper material into two rectangular conductive plates 10, cutting the insulating plugs 31 according to the structure of the outer walls on both sides of the conductive plates 10, and the length of the insulating plugs 31 is 40% of the length of the conductive plates 10.

[0034] B. Level and arrange. The conductive plates 10 are arranged flatly at intervals in the width direction, and two insulating plugs 31 are embedded into the conductive plates 10 to form two ends of the gap, so that the two sides of the insulating plugs 31 are tightly attached to the outer wall of the conductive plates 10 and the ends of the insulating plugs 31 are flush with the surface of one side of the conductive plates 10.

[0035] C. Pressing and bending. Place the two insulating films 20 on both sides of the flattened conductive plate 10 and the insulating plug 31 respectively, and combine them into an integral module by hot pressing. Clamp the two ends of the integral module in the length direction, with the clamping length of both ends equal to the length of the insulating plug 31, and bend the conductive plate 10 along the midline of the length of the conductive plate 10.

[0036] D. Opening holes for potting: at least one potting opening 21 is opened on the insulating film 20 between the two insulating plugs 31 , and potting glue 32 is filled into the L-shaped groove 11 through the potting opening 21 .

[0037] This processing method does not require bending of the insulating plug 31, which reduces the processing difficulty and has strong versatility. It is applicable to insulating structures 30 in various situations and does not require the development of molds for manufacturing different types of insulating plugs 31 and covering the surface insulating film 20, thereby reducing R&D and production costs, having high work efficiency and being applicable to large-scale industrial production.

[0038] Embodiment 2

[0039] like Figure 5As shown, the structure and principle of this embodiment are basically the same as those of the first embodiment, so they are not described here in detail. The difference is that the limiting structure 33 includes two arc-shaped concave surfaces arranged on the outer wall of the conductive plate 10 located in the strip groove 12, and two arc-shaped convex surfaces 334 respectively arranged on both sides of the insulating plug 31 and correspondingly fitted with the arc-shaped concave surfaces 333. Through the cooperation of the arc-shaped convex surfaces 334 and the arc-shaped concave surfaces 333, the insulating plug 31 can be stably embedded between the conductive plates 10, and the structure is compact and reliable. It can be imagined that the arc-shaped convex surface 334 and the arc-shaped concave surface 333 can also be replaced by a V-shaped surface structure.

[0040] The above are only preferred embodiments of the present invention and are not intended to limit the protection scope of the present invention. Any modification, equivalent substitution or improvement within the spirit of the present invention is included in the scope of the claims of the present invention.

Claims

1. A new type of combined insulated busbar structure, characterized by: The novel combined insulating busbar structure includes at least two conductive plates arranged at intervals, two insulating films respectively arranged on both sides of the conductive plates arranged at intervals, and at least one insulating structure arranged between the conductive plates. At least one corresponding bending portion is provided on the conductive plate, an L-shaped groove close to the bending portion is formed between two adjacent conductive plates and the insulating film, and two strip grooves arranged at both ends of the L-shaped groove and connected to the L-shaped groove. The insulating structure includes two insulating plugs respectively embedded in the strip grooves, and a potting glue filled in the L-shaped groove. The circumferential edge of the insulating film protrudes from the outermost circumferential edge of the conductive plate arranged at intervals, and a potting port connected to the L-shaped groove is provided on the side of the insulating film close to the bending portion.

2. The novel combined insulated busbar structure according to claim 1 is characterized in that: The insulating plug is matched with the strip groove structure and two sides of the insulating plug fit tightly against the outer wall of the conductive plate.

3. The novel combined insulated busbar structure according to claim 1 is characterized in that: A limiting structure is provided between the insulating plug and the conductive plate.

4. The novel combined insulated busbar structure as claimed in claim 3 is characterized in that: The limiting structure includes two positioning grooves arranged on the outer wall of the conductive plate located in the L-shaped groove, and two positioning protrusions respectively arranged on both sides of the insulating plug and correspondingly inserted into the positioning grooves.

5. The novel combined insulated busbar structure as claimed in claim 3 is characterized in that: The limiting structure includes two arc-shaped concave surfaces arranged on the outer wall of the conductive plate located in the strip-shaped groove, and two arc-shaped convex surfaces respectively arranged on two sides of the insulating plug and correspondingly fitting the arc-shaped concave surfaces.

6. The novel combined insulated busbar structure according to claim 1 is characterized in that: One end of the insulating plug away from the L-shaped groove is flush with a side surface of the conductive plate.

7. The novel combined insulated busbar structure according to claim 1 is characterized in that: The length of the insulating plug is 30%-40% of the length of the conductive plate.

8. The processing method of the novel combined insulating busbar structure according to any one of claims 1 to 7, characterized in that: The processing steps are as follows: A. Cutting and blanking: stamping the copper material into two rectangular conductive plates, cutting and processing the insulating plugs according to the structure of the outer walls on both sides of the conductive plates. The length of the insulating plugs is 40% of the length of the conductive plates; B. Leveling and arranging: the conductive plates are arranged in a flat manner at intervals in the width direction, and two insulating plugs are embedded in the two ends of the gap formed by the conductive plates, so that the two sides of the insulating plugs are closely attached to the outer wall of the conductive plates and the ends of the insulating plugs are flush with the surface of one side of the conductive plates; C. Pressing and bending: placing two insulating films on both sides of the flattened conductive plate and the insulating plug respectively, and combining them into an integral module by hot pressing, clamping both ends of the integral module in the length direction, with the clamping length of both ends being equal to the length of the insulating plug, and bending the conductive plate along the midline of the length of the conductive plate; D. Opening holes for potting: at least one potting opening is opened on the insulating film between the two insulating plugs, and the potting glue is filled into the L-shaped groove through the potting opening.

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