Multi-layer composite anti-corrosion waterproof battery connection assembly and preparation method thereof

Abstract

The invention discloses a multi-layer composite anti-corrosion waterproof battery connection assembly and a preparation method thereof, and belongs to the field of new energy, the multi-layer composite anti-corrosion waterproof battery connection assembly comprises a sleeve, a busbar, a locking bolt and a sealing ring, the busbar is installed in the sleeve, the sealing ring is installed between the busbar and the sleeve, and the busbar located in the sleeve is fixed through the locking bolt; the busbar comprises a metal layer, insulating layers and an anti-corrosion outer layer, the insulating layers are arranged on the two sides of the metal layer, the anti-corrosion outer layer is arranged on the side, away from the metal layer, of each insulating layer, and the thickness of the anti-corrosion outer layer ranges from 0.1 mm to 5 mm; the anti-corrosion outer layer is composed of a high polymer material, the high polymer material comprises rubber, PVC, PP and epoxy resin, the anti-corrosion outer layer is of a multi-layer structure, the inner layer is an epoxy resin layer, the outer layer is rubber, PP or PVC, the material mass ratio is 20-60 parts of the inner layer epoxy resin, and the material mass ratio is 40-80 parts of the outer layer rubber, PP or PVC, and the safety and reliability of the immersed cooling technology can be remarkably improved.

Description

Technical Field

[0001] The present invention belongs to the field of new energy technology and relates to the technical field of energy storage battery pack parts and accessories, and specifically relates to a multi-layer composite anti-corrosion and waterproof battery connection component and a preparation method thereof. Background Art

[0002] New energy battery packs usually refer to battery systems that provide energy storage and power output for new energy vehicles such as electric vehicles and hybrid vehicles. New energy battery packs are one of the core components of new energy vehicles, and their performance directly affects the vehicle's range, safety and economy. With the development of technology, the design and manufacture of battery packs are moving towards higher energy density, faster charging speed and longer life.

[0003] Immersion cooling technology is an efficient thermal management method that achieves rapid heat transfer and dissipation by immersing electronic equipment directly in coolant. Figure 1 The busbars of traditional battery connection components are generally used with insulating layers on both sides of the metal layer. The insulation layer requires a fire protection level of UL94V0. It is prone to corrosion, oxidation and electrical failure when immersed in coolant for a long time, resulting in low reliability and stability of the system. Summary of the invention

[0004] The object of the present invention is to provide a multi-layer composite anti-corrosion and waterproof battery connection assembly to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] A multi-layer composite anti-corrosion and waterproof battery connection component,

[0007] It comprises a sleeve, a busbar, a locking bolt and a sealing ring, wherein the busbar is installed inside the sleeve, the sealing ring is installed between the busbar and the sleeve, and the busbar inside the sleeve is fixed by the locking bolt;

[0008] The busbar includes a metal layer, an insulating layer and an anti-corrosion outer layer. The insulating layer is arranged on both sides of the metal layer. The side of the insulating layer away from the metal layer is the anti-corrosion outer layer, and the thickness of the anti-corrosion outer layer is 0.1mm~5mm; the anti-corrosion outer layer is composed of polymer materials, and the polymer materials include rubber, PVC, PP, and epoxy resin. The anti-corrosion outer layer is a multi-layer structure, the inner layer is an epoxy resin layer, and the outer layer is rubber, PP or PVC, wherein the material mass ratio is 20~60 parts of the inner layer epoxy resin and 40~80 parts of the outer layer rubber, PP or PVC.

[0009] Preferably, anti-corrosion coatings are provided on both sides of the metal layer, the thickness of the anti-corrosion coatings is 0.1 μm to 50 μm, and the anti-corrosion coatings are metal material coatings or organic material coatings; when metal material coatings are used, the metal material coatings use electroplating or chemical plating to deposit a corrosion-resistant nickel or tin metal layer on the metal layer, and then a layer of silver or gold coating is deposited by PVD or CVD, wherein the material composition of the anti-corrosion metal coating contains 90 to 99 parts of nickel or tin metal components, and 1 to 10 parts of gold or silver components; when organic material coatings are used, wherein the organic material coatings are composed of polymer materials, and the polymer materials selected are epoxy resins.

[0010] Preferably, the metal layer is composed of one or more of copper, aluminum, nickel, steel and titanium, and the thickness of the metal layer is 1 mm to 100 mm.

[0011] Preferably, the insulating layer is composed of polymer materials, and the polymer materials include PVC, PP, PE, PET and PI.

[0012] Preferably, the anti-corrosion outer layer is composed of heat shrinkable rubber and rubber tube.

[0013] Preferably, the anti-corrosion coating is a corrosion-resistant metal coating or a thin polymer material coating.

[0014] Preferably, the corrosion-resistant metal coating consists of nickel, tin, silver and gold.

[0015] Preferably, the thin polymer material coating is composed of epoxy resin.

[0016] A method for preparing a multi-layer composite anti-corrosion and waterproof battery connection assembly comprises the following steps:

[0017] S1. Material preparation:

[0018] Select conductive metal materials, select polymer anti-corrosion materials or corrosion-resistant metal layers, and prepare insulating layer materials;

[0019] S2. Metal layer forming: metal materials are processed into the required connector shape and the metal surface is cleaned; the metal material processing technology is one or more of casting, profile extrusion, 3D printing, powder metallurgy, stamping, laser cutting, machining, welding, riveting and other processes.

[0020] S3. Anti-corrosion coating is applied, the anti-corrosion coating is evenly deposited on the metal layer, and the coating is cured; the anti-corrosion coating processing technology is one or more of PVD, CVD, electroplating, chemical plating, electrophoresis, painting, powder spraying, dipping, ultrasonic powder deposition and the like.

[0021] S4, insulation layer coating, coating insulation material on the metal anti-corrosion layer, and curing the insulation layer; the insulation layer processing technology is one or more of spray painting, powder spraying, plastic dipping, plastic tape winding, injection molding, insulating plastic shell nesting and the like.

[0022] S5. A polymer anti-corrosion outer layer is coated with polymer materials to ensure overall sealing; the process of the polymer anti-corrosion outer layer is one or more of powder spraying, plastic dipping, plastic tape winding, injection molding, insulating plastic shell nesting and the like.

[0023] S6, embedded seal design, processing embedded seal structure to ensure the tightness of the position;

[0024] S7. Product testing and verification, corrosion resistance test, waterproof performance test, and electrical performance test; the waterproof test is conducted using the IP67 test standard, the corrosion resistance test is conducted using the salt spray test standard, and the electrical performance meets the insulation requirements of no less than 3000VDC in the current electrical system of new energy vehicles.

[0025] Technical effects and advantages of the present invention:

[0026] 1) The present invention has high durability. The busbar composed of a metal layer, an insulating layer, and an anti-corrosion outer layer has extremely high corrosion resistance and durability in an immersion cooling environment, extending the service life of the component. It is directly immersed in the coolant, especially in the case of high-rate discharge when the conductor heat is sharply increased in the traditional cooling method, to achieve a more uniform temperature distribution, prevent local overheating, and have excellent thermal management performance. Since the product has anti-corrosion, insulation and waterproof properties that current ordinary products do not have, it can be used in electrical connection scenarios in immersion liquid cooling environments in terms of waterproof performance, corrosion resistance and insulation performance.

[0027] (2) The waterproof layer and insulating layer of the busbar of the present invention, together with the sleeve and the sealing ring, can effectively prevent the coolant from entering the electrical part, reduce the risk of short circuit and electrical failure, and improve the safety of the system.

[0028] (3) The present invention can be customized according to different application scenarios and requirements, is applicable to a variety of liquid cooling technology scenarios, has broad market application prospects, and has wide applicability. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a structural schematic diagram of a busbar in the background technology;

[0030] Figure 2 It is a schematic diagram of the structure of the busbar in the present invention;

[0031] Figure 3 It is a schematic diagram of the overall structure of the present invention;

[0032] Figure 4 It is a flowchart of the present invention.

[0033] In the figure: 1. sleeve; 2. busbar; 21. metal layer; 22. insulating layer; 23. anti-corrosion outer layer; 24. anti-corrosion coating; 3. locking bolt; 4. sealing ring. DETAILED DESCRIPTION

[0034] The following will be combined with the attached embodiment of the present invention Figure 2-Figure 4 , the technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0035] Example

[0036] like Figure 2-Figure 4 As shown, a multi-layer composite anti-corrosion and waterproof battery connection component includes a sleeve 1, a busbar 2, a locking bolt 3 and a sealing ring 4. The busbar 2 is installed inside the sleeve 1, and the sealing ring 4 is installed between the busbar 2 and the sleeve 1. The busbar 2 located inside the sleeve 1 is fixed by the locking bolt 3. An embedded sealing structure is used at the joint part of the component to ensure that a full range of waterproof sealing is achieved during the connection process to prevent the coolant from penetrating into the electrical connection part;

[0037] The busbar 2 includes a metal layer 21, an insulating layer 22 and an anti-corrosion outer layer 23. The insulating layer 22 is disposed on both sides of the metal layer 21. The side of the insulating layer 22 away from the metal layer 21 is the anti-corrosion outer layer 23. The thickness of the anti-corrosion outer layer 23 is 0.1 mm to 5 mm. The anti-corrosion outer layer 23 is composed of polymer materials, including rubber, PVC, PP, and epoxy resin. The anti-corrosion outer layer 23 is a multi-layer structure, the inner layer is an epoxy resin layer, and the outer layer is rubber, PP or PVC. The material weight ratio is 20 to 60 parts of the inner layer epoxy resin and 40 to 80 parts of the outer layer rubber, PP or PVC. The metal layer 21 with strong electrical conductivity and excellent thermal conductivity is used inside, and the outer layer is coated with a corrosion-resistant and waterproof polymer material layer. The outermost layer is an insulating protective layer to effectively prevent electrical short circuits and signal interference.

[0038] Anti-corrosion coatings 24 are also provided on both sides of the metal layer 21. The thickness of the anti-corrosion coating 24 is 0.1μm to 50μm. The anti-corrosion coating 24 is a metal material coating or an organic material coating. When a metal material coating is used, the metal material coating uses electroplating or chemical plating to deposit a corrosion-resistant nickel or tin metal layer 21 on the metal layer 21, and then deposits a layer of silver or gold coating by PVD or CVD, wherein the material composition of the anti-corrosion metal coating contains 90 to 99 parts of nickel or tin metal components, and 1 to 10 parts of gold or silver components. When an organic material coating is used, wherein the organic material coating is composed of a polymer material, epoxy resin is selected as the polymer material, and a special anti-corrosion coating 24 is applied to the metal layer 21. This coating can resist the corrosion of the coolant, and a metal coating or an organic material coating can be selected.

[0039] The metal layer 21 is composed of copper, aluminum, nickel, steel and titanium, and the thickness of the metal layer 21 is 1 mm to 100 mm.

[0040] The insulating layer 22 is composed of polymer materials, including PVC, PP, PE, PET and PI.

[0041] The anticorrosive outer layer 23 is composed of heat shrinkable resin and rubber tube.

[0042] The anti-corrosion coating 24 is made of corrosion-resistant metal coating or thin polymer material coating.

[0043] The corrosion-resistant metal coating consists of nickel, tin, silver and gold.

[0044] The thin polymer coating consists of epoxy resin.

[0045] A method for preparing a multi-layer composite anti-corrosion and waterproof battery connection assembly comprises the following steps:

[0046] S1. Material preparation:

[0047] Select a conductive metal material, select a polymer anti-corrosion material or a corrosion-resistant metal layer 21, and prepare an insulating layer 22 material;

[0048] S2. Metal layer forming: metal materials are processed into the required connector shape and the metal surface is cleaned; the metal material processing technology is one or more of casting, profile extrusion, 3D printing, powder metallurgy, stamping, laser cutting, machining, welding, riveting and other processes.

[0049] S3, anti-corrosion coating is applied, anti-corrosion coating 24 is evenly deposited on metal layer 21, and the coating is cured; the processing technology of anti-corrosion coating 24 is one or more of PVD, CVD, electroplating, chemical plating, electrophoresis, painting, powder spraying, dipping, ultrasonic powder deposition and the like.

[0050] S4, insulation layer coating, coating insulation material on the metal anti-corrosion layer, and curing the insulation layer 22; the processing technology of the insulation layer 22 is one or more of the processes such as painting, powder spraying, dipping, winding plastic tape, injection molding, and insulating plastic shell nesting.

[0051] S5, polymer anti-corrosion outer layer, coated with polymer materials to ensure overall sealing; the process of the polymer anti-corrosion outer layer 23 is one or more of powder spraying, dipping, winding plastic tape, injection molding, insulating plastic shell nesting and the like.

[0052] S6, embedded seal design, processing embedded seal structure to ensure the tightness of the position;

[0053] S7. Product testing and verification, corrosion resistance test, waterproof performance test, and electrical performance test; the waterproof test is conducted using the IP67 test standard, the corrosion resistance test is conducted using the salt spray test standard, and the electrical performance meets the insulation requirements of no less than 3000VDC in the current electrical system of new energy vehicles.

[0054] In summary, the present invention has high durability, excellent thermal management performance, and reliable waterproofness.

[0055] Example 1

[0056] The metal layer 21 is pure copper; the anti-corrosion coating 24 is 99 parts of electroplated nickel and 1 part of PVD deposited silver; the insulating layer 22 is powder-sprayed epoxy resin; the anti-corrosion outer layer 23 is 20 parts of dipped powder epoxy resin, and the outermost layer is 80 parts of dip-plastic PVC.

[0057] Comparative Example 1

[0058] The metal layer 21 is pure copper; the insulating layer 22 is powder-sprayed epoxy resin.

[0059] Comparative Example 1 has no anti-corrosion coating 24, and the surface corrosion is severe after the salt spray test; the insulating layer 22 covers only part of the area, and during immersion cooling, the metal layer 21 is exposed to the coolant, and the coolant directly contacts the electrical connection joints, posing a high risk.

[0060] In Example 1, the anti-corrosion layer covers the metal layer 21 as a whole, and there is no corrosion on the surface after the salt spray test; the insulating layer 22 and the anti-corrosion outer layer 23 cover the entire position except the joint, and the joint is connected by an embedded sealing structure. The sealing rubber ring in the embedded sealing structure after locking is compressed and deformed, isolating the connection between the joint and the coolant, and the coolant cannot contact the electrical connection joint. At the same time, since the metal layer 21 body is fully covered with the anti-corrosion metal layer 21, part of the coolant vapor entering the electrical connection joint space during operation will not affect the electrical performance of the joint.

[0061] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A multi-layer composite anti-corrosion and waterproof battery connection assembly, characterized in that: It comprises a sleeve (1), a busbar (2), a locking bolt (3) and a sealing ring (4), wherein the busbar (2) is installed inside the sleeve (1), the sealing ring (4) is installed between the busbar (2) and the sleeve (1), and the busbar (2) located inside the sleeve (1) is fixed by the locking bolt (3); The busbar (2) comprises a metal layer (21), an insulating layer (22) and an anti-corrosion outer layer (23), wherein the insulating layer (22) is disposed on both sides of the metal layer (21), and the side of the insulating layer (22) away from the metal layer (21) is the anti-corrosion outer layer (23), and the thickness of the anti-corrosion outer layer (23) is 0.1 mm to 5 mm; the anti-corrosion outer layer (23) is composed of a polymer material, wherein the polymer material comprises rubber, PVC, PP, and epoxy resin; the anti-corrosion outer layer (23) is a multi-layer structure, wherein the inner layer is an epoxy resin layer, and the outer layer is rubber, PP or PVC, wherein the material weight ratio is 20 to 60 parts of the inner layer epoxy resin and 40 to 80 parts of the outer layer rubber, PP or PVC.

2. A multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 1, characterized in that: An anti-corrosion coating (24) is provided on both sides of the metal layer (21), the thickness of the anti-corrosion coating (24) is 0.1 μm to 50 μm, and the anti-corrosion coating (24) is a metal material coating or an organic material coating; when a metal material coating is used, the metal material coating uses electroplating or chemical plating to deposit a corrosion-resistant nickel or tin metal layer (21) on the metal layer (21), and then deposits a layer of silver or gold coating by PVD or CVD, wherein the material composition of the anti-corrosion metal coating contains 90 to 99 parts of nickel or tin metal components and 1 to 10 parts of gold or silver components; When an organic material coating is used, wherein the organic material coating is composed of a polymer material, epoxy resin is selected as the polymer material.

3. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 1, characterized in that: The metal layer (21) is composed of one or more of copper, aluminum, nickel, steel and titanium, and the thickness of the metal layer (21) is 1 mm to 100 mm.

4. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 1, characterized in that: The insulating layer (22) is composed of a polymer material, and the polymer material includes PVC, PP, PE, PET and PI.

5. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 1, characterized in that: The anti-corrosion outer layer (23) is composed of heat shrinkable resin and rubber tube.

6. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 2, characterized in that: The anti-corrosion coating (24) is a corrosion-resistant metal coating or a thin polymer material coating.

7. A multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 6, characterized in that: The corrosion-resistant metal coating consists of nickel, tin, silver and gold.

8. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 6, characterized in that: The thin polymer material coating is composed of epoxy resin.

9. A method for preparing a multi-layer composite anti-corrosion and waterproof battery connection assembly, characterized in that: The following steps are involved: The following steps are involved: S1. Material preparation: Selecting a conductive metal material, selecting a polymer anti-corrosion material or a corrosion-resistant metal layer (21), and preparing an insulating layer (22) material; S2. Metal layer forming: metal materials are processed into the required connector shape and the metal surface is cleaned; the metal material processing technology is one or more of casting, profile extrusion, 3D printing, powder metallurgy, stamping, laser cutting, machining, welding, riveting and other processes. S3, applying an anti-corrosion coating, uniformly depositing the anti-corrosion coating (24) on the metal layer (21), and curing the coating; the processing technology of the anti-corrosion coating (24) is one or more of PVD, CVD, electroplating, chemical plating, electrophoresis, painting, powder spraying, dipping, ultrasonic powder deposition and the like. S4, coating of the insulating layer, coating the insulating material on the metal anti-corrosion layer, and curing the insulating layer (22); the processing technology of the insulating layer (22) is one or more of the processes such as spray painting, powder spraying, dipping, winding plastic tape, injection molding, and nesting of insulating plastic shells. S5, a polymer anti-corrosion outer layer, coated with polymer materials to ensure overall sealing; the process of the polymer anti-corrosion outer layer (23) is one or more of powder spraying, dipping, winding plastic tape, injection molding, insulating plastic shell nesting and the like. S6, embedded seal design, processing embedded seal structure to ensure the tightness of the position; S7. Product testing and verification, corrosion resistance test, waterproof performance test, and electrical performance test; the waterproof test is conducted using the IP67 test standard, the corrosion resistance test is conducted using the salt spray test standard, and the electrical performance meets the insulation requirements of no less than 3000VDC in the electrical system of new energy vehicles. Since the product has anti-corrosion, insulation, and waterproof properties that are not currently available in ordinary products, it is suitable for electrical connection scenarios in immersion liquid cooling environments in terms of waterproof performance, corrosion resistance, and insulation performance.

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