Copper busbar for vehicle-mounted DC-DC converter with excessive current and vehicle-mounted DC-DC converter

Abstract

The present invention relates to a copper busbar for an on-board DC-DC converter with excessive current and an on-board DC-DC converter. A copper busbar for an on-board DC-DC converter with excessive current comprises a sheet-shaped first extension section and a second extension section, wherein the second extension section is located on one side of the width direction of the first extension section, one end of the first extension section is used to be fixed to a fixed portion, the other end of the first extension section is connected to one end of the second extension section, and the other end of the second extension section is used to be connected to a circuit board, the first extension section is provided with a first extension groove extending along its own length direction, the second extension section is provided with a second extension groove extending along its own length direction, the first extension groove is connected to the second extension groove through a connecting groove near the second extension section, the connecting groove is located on the first extension section and runs through the first extension section, and the connecting groove corresponds to the first extension groove and the second extension groove one by one. The present invention can avoid the situation where the copper busbar pin is twisted and pulled due to excessive force when tightening the bolt fastener, and the present invention has the advantage of good electrical connection stability of the copper busbar.

Description

Technical Field

[0001] The invention relates to a DC-DC converter of an electric vehicle, and in particular to a copper busbar for an over-current vehicle-mounted DC-DC converter and a vehicle-mounted DC-DC converter. Background Art

[0002] When working, the DC-DC converter, especially the converter designed for high-power applications in vehicles, needs to carry a large current. In order to improve the stability of the electrical connection, one end of the copper busbar is welded and fixed to the circuit board, and the other end of the copper busbar is fixed in the DC-DC converter housing by fasteners.

[0003] When the copper busbar is fixed by bolt fasteners, if the tightening force of the bolt fasteners is low, it will cause the connection failure. If the tightening force is large, it may cause the copper busbar to deform, thereby affecting the connection at the pin, which is not conducive to the use of excessive current. Summary of the invention

[0004] The object of the present invention is to provide a copper busbar for an on-vehicle DC-DC converter which is easy to fix by a fastener and does not affect the normal use of the copper busbar.

[0005] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a copper busbar for an on-board DC-DC converter with excessive current, comprising a sheet-shaped first extension section and a second extension section, the second extension section being located on one side in the width direction of the first extension section, one end of the first extension section being used to be fixed to a fixing part by a fastener, the other end of the first extension section being connected to one end of the second extension section, the other end of the second extension section having a pin and being used to be connected to a circuit board, the first extension section being provided with a plurality of first extension grooves extending along its own length direction and penetrating therethrough, the second extension section being provided with a plurality of second extension grooves extending along its own length direction and penetrating therethrough, the first extension groove being connected to the second extension groove through a connecting groove near the second extension section, the connecting groove being located on the first extension section and penetrating the first extension section, the connecting groove corresponding to the first extension groove and the second extension groove one by one.

[0006] In the scheme of the present invention, by providing a plurality of extension grooves on the first extension section and the second extension section, the flexibility of the copper bar can be increased, the deformation of the copper bar caused by stress concentration during the fastening process can be reduced, and the copper bar pins can be twisted and pulled due to excessive force when tightening the bolt fasteners, thereby facilitating the fastener fixation of the copper bar and ensuring the electrical connection and normal use of the copper bar; the design of the extension groove helps to better distribute the stress when the copper bar is subjected to the fastening force, and reduce the deformation of the copper bar caused by excessive fastening force, thereby affecting the connection at the pins; the extension groove design of the copper bar can increase the surface area of ​​the copper bar, thereby improving the thermal conductivity efficiency of the copper bar, helping to dissipate heat and reduce the operating temperature. Among them, the fixed part can be any terminal or connector or other copper bar for connecting electricity located in the shell of the vehicle-mounted DC-DC converter.

[0007] Preferably, the number of the first extension grooves and the second extension grooves is at least two, the distance between two adjacent first extension grooves is greater than the width of the first extension groove, the distance between two adjacent second extension grooves is greater than the width of the second extension groove, and the distance between two adjacent connecting grooves is greater than the width of the connecting groove.

[0008] The number of the first extension grooves and the second extension grooves is at least two, which increases the flexibility of the copper busbar, reduces deformation caused by the fastening force, and ensures the stability of the electrical connection. The distance between two adjacent first extension grooves is greater than the width of the first extension grooves, and the second extension grooves and the connecting grooves are designed in the same way, which can ensure that when the copper busbar is subjected to the fastening force, the grooves will not affect each other, reduce overall distortion and deformation, and maintain the reliability of the electrical connection.

[0009] Preferably, the connecting groove is an arc groove. The design of the arc groove can better adapt to the stress distribution of the copper busbar, reduce stress concentration points, and avoid the copper busbar from breaking due to excessive local stress.

[0010] Preferably, a notch is formed at the edge of the first extension section near the second extension section. The notch design can reduce local stress concentration of the copper bar, avoid excessive deformation of the second extension section of the copper bar when the copper bar is fixed by bolt fasteners, and avoid negative impact on the fixation of the pins.

[0011] Preferably, the length of the second extension groove is at least half of the length of the second extension section, which helps to improve the strength and stability of the copper busbar, especially when a large current passes through it, so that it can better withstand electrical stress.

[0012] Preferably, the pin surface is concave to form a matching groove, and the surfaces of the first extension section, the second extension section and the matching groove wall are all tinned. By providing the matching groove, the tinning amount is increased, the tinning fullness is improved, and the situation that the tinning amount in the plug-in hole of the circuit board does not meet the requirements due to the high thermal conductivity of the copper bar in the welding process, which causes the heat of the molten solder to be quickly transferred away, is avoided.

[0013] Preferably, the matching groove extends along the extension direction of the pin. During soldering, the tin can climb along the matching groove to ensure the fullness of the tin on the matching hole of the circuit board and the pin.

[0014] Preferably, at least two matching grooves are arranged side by side at the pin. By providing at least two matching grooves, the width of the matching groove is reduced, thereby ensuring the tinning effect.

[0015] The present invention also discloses a vehicle-mounted DC-DC converter having the above-mentioned copper busbar, comprising a shell, the circuit board being located inside the shell, a positioning notch being formed on the side edge of the first extension section deviating from the end, a U-shaped filtering magnetic ring being arranged on the outer sleeve of the first extension section, and the filtering magnetic ring being located at the positioning notch.

[0016] The positioning notch is provided to play a positioning and limiting role, so that the filter magnetic ring can be easily fixed on the copper busbar, and the filter magnetic ring can be set closer to the positive pole. The U-shaped filter magnetic ring can reduce electromagnetic interference and improve the electromagnetic compatibility of the DC-DC converter, especially in high-power applications, where the role of the filter magnetic ring is particularly important. Among them, the filter magnetic ring can be fixed on the copper busbar by existing methods such as glue fixation.

[0017] Preferably, the first extension section is provided with positioning notches on both sides, and the two positioning notches are symmetrically arranged. The positioning notches are provided on both sides, so that the filter magnetic ring can be easily installed from both sides of the copper busbar.

[0018] The present invention can avoid the situation where the copper busbar pins are twisted and pulled due to excessive force when tightening the bolt fasteners, and the present invention has the advantage of ensuring good electrical connection stability of the copper busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of the copper busbar of the present invention.

[0020] Figure 2 The present invention is a schematic structural diagram of the internal copper busbar of the vehicle-mounted DC-DC converter. DETAILED DESCRIPTION

[0021] The present invention will be further described below based on the accompanying drawings and specific embodiments.

[0022] Depend on Figure 1 and Figure 2 As shown, the present embodiment discloses a vehicle-mounted DC-DC converter and a copper busbar for a vehicle-mounted DC-DC converter with excessive current, comprising a sheet-shaped first extension section 1 and a second extension section 2, the second extension section 2 being located on one side of the first extension section 1 in the width direction, the extension direction of the first extension section 1 being perpendicular to the extension direction of the second extension section 2, one end of the first extension section 1 being used for fixing with a fixing part, the fixing part of the present embodiment being a power connector 91, the other end of the first extension section 1 being connected with one end of the second extension section 2, the other end of the second extension section 2 having a pin 20 and being connected with a circuit board, wherein the first extension section 1 of the copper busbar of the present embodiment is fixed in a housing 93 of the vehicle-mounted DC-DC converter by a fastener 92, the end of the first extension section 1 away from the second extension section 2 being provided with a matching hole 14 penetrating from top to bottom for matching with a bolt-type fastener, a circuit board 94 being provided in the housing 93, and a pin 20 for connecting with the circuit board 94 being provided at the second extension section 2.

[0023] The first extension section 1 is provided with two first extension grooves 11 extending along its length direction and penetrating vertically, and the second extension section 2 is provided with two second extension grooves 21 extending along its length direction and penetrating front and back. The first extension groove 11 is connected to the second extension groove 21 through a connecting groove 12 near the second extension section 2. The connecting groove 12 is located on the first extension section 1 and penetrates the first extension section 1 vertically. The connecting groove 12 corresponds to the first extension groove 11 and the second extension groove 21 one by one. Among them, the distance between two adjacent first extension grooves 11 is greater than the width of the first extension groove 11, the distance between two adjacent second extension grooves 21 is greater than the width of the second extension groove 21, and the distance between two adjacent connecting grooves 12 is greater than the width of the connecting groove 12. The connecting groove 12 is an arc groove and forms a 90° angle.

[0024] In this embodiment, a notch 10 is formed at the edge of the first extension section 1 adjacent to the second extension section 2 . The width of the notch 10 is smaller than the width of the first extension groove 11 . The length of the second extension groove 21 is at least two-thirds of the length of the second extension section 2 .

[0025] In this embodiment, two pins 20 are provided on both sides of the lower end of the second extension section 2. The surface of each pin 20 is concave to form two matching grooves 201 extending side by side and vertically. The surfaces of the first extension section 1, the second extension section 2 and the groove walls of the matching grooves 201 are all tin-plated.

[0026] A positioning notch 13 is formed at the side edge of the first extension section 1 at the end thereof, and a U-shaped filter magnetic ring 3 is disposed on the outer cover of the first extension section 1, and the filter magnetic ring 3 is located at the positioning notch 13. The first extension section 1 has positioning notches 13 on opposite sides, and the two positioning notches 13 are symmetrically arranged.

[0027] This embodiment can reduce the negative impact on the pins caused by excessive tightening force when installing the copper busbar, and has the advantage of ensuring good electrical connection stability of the copper busbar.

Claims

1. A copper busbar for an on-board DC-DC converter with excessive current, comprising a sheet-shaped first extension section and a second extension section, wherein the second extension section is located on one side of the width direction of the first extension section, one end of the first extension section is used to be fixed to a fixing part by a fastener, the other end of the first extension section is connected to one end of the second extension section, and the other end of the second extension section has a pin and is used to be connected to a circuit board, characterized in that: The first extension section is provided with a plurality of first extension grooves extending along and penetrating the first extension section, and the second extension section is provided with a plurality of second extension grooves extending along and penetrating the first extension section. The first extension groove is connected to the second extension groove through a connecting groove near the second extension section. The connecting groove is located on the first extension section and penetrating the first extension section, and the connecting groove corresponds one-to-one to the first extension groove and the second extension groove.

2. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 1, characterized in that: The number of the first extension grooves and the second extension grooves is at least two, the distance between two adjacent first extension grooves is greater than the width of the first extension groove, the distance between two adjacent second extension grooves is greater than the width of the second extension groove, and the distance between two adjacent connecting grooves is greater than the width of the connecting groove.

3. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 1 or 2, characterized in that: The connecting groove is an arc-shaped groove.

4. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 1 or 2, characterized in that: A notch is formed at the edge of the first extension section adjacent to the second extension section.

5. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 1 or 2, characterized in that: The length of the second extension groove is at least half of the length of the second extension section.

6. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 1, characterized in that: The surface of the pin is concave to form a matching groove, and the surfaces of the first extension section, the second extension section and the wall of the matching groove are all tin-plated.

7. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 6, characterized in that: The matching groove extends along the extending direction of the pin.

8. The copper busbar for an over-current vehicle-mounted DC-DC converter according to claim 6, characterized in that: The pin is provided with at least two matching grooves arranged side by side.

9. A vehicle-mounted DC-DC converter having the copper busbar according to any one of claims 1 to 8, comprising a housing, wherein the circuit board is located in the housing, and characterized in that: A positioning notch is formed at a side edge of the first extension section where the end portion deviates therefrom. A U-shaped filtering magnetic ring is disposed on the outer sleeve of the first extension section. The filtering magnetic ring is located at the positioning notch.

10. The vehicle-mounted DC-DC converter according to claim 9, characterized in that: The first extension section is provided with positioning notches on opposite sides, and the two positioning notches are symmetrically arranged.

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