Halogen-free soft busbar structure

Abstract

The invention belongs to the technical field of busbars, and particularly relates to a halogen-free soft busbar structure which comprises a protective outer body and a confluence body. The confluence body comprises at least two stacked confluence metal sheets; all the confluence metal sheets penetrate through the interior of the protective outer body, and all the confluence metal sheets are connected to the interior of the protective outer body; the halogen-free soft busbar structure is provided with a bending section and an end section; and when the halogen-free soft busbar structure is in a bent state and in the end section, the projection of each convergence metal sheet towards the protective outer body and the protective outer body are at least partially overlapped or staggered. According to the invention, the use safety and stability can be guaranteed, the advantages of reasonable and compact structure, beautiful appearance and the like can be realized, and meanwhile, large current-carrying capacity and more excellent heat dissipation and insulation can be realized.

Description

Technical Field

[0001] The invention belongs to the technical field of busbars, and in particular relates to a halogen-free soft busbar structure. Background Art

[0002] The soft-connected halogen-free soft busbar structure (conductor) is widely used in new energy vehicles, power systems, AC motor control systems, switch transformers and other fields due to its strong conductivity, large current bearing, small AC resistance, durability and high reliability.

[0003] However, when a fire occurs, the traditional busbar is easily decomposed after being heated, emitting a large amount of highly toxic and corrosive HCL (hydrogen chloride) gas, and producing a large amount of highly toxic smoke, causing significant loss of life and property, and bringing great difficulties to rescue work; in addition, the overall structural stability and compactness are poor, and it is easy to disintegrate. Summary of the invention

[0004] The purpose of the present invention is to provide a halogen-free flexible busbar structure to address the deficiencies of the prior art, and to solve the technical problems of the prior art in terms of overall structural stability and poor compactness.

[0005] In order to achieve the above object, the present invention adopts the following technical solution:

[0006] A halogen-free flexible busbar structure, comprising a protective outer body and a busbar; the busbar comprises at least two stacked busbar metal sheets; all the busbar metal sheets pass through the interior of the protective outer body, and all the busbar metal sheets are connected to the interior of the protective outer body; the halogen-free flexible busbar structure is provided with a bending section and an end section;

[0007] When the halogen-free flexible busbar structure is in a bent state and in the end section, a projection of each of the busbar metal sheets toward the protective outer body is at least partially overlapped or staggered with the protective outer body.

[0008] Preferably, in the bending section, a projection of each of the busbar metal sheets toward the protective outer body is arranged to overlap with the protective outer body; and the outermost busbar metal sheets abut against the inner wall of the protective outer body.

[0009] Preferably, the bending section includes at least two straight portions, at least one winding bending portion and at least one arc-shaped bending portion; the winding bending portion is arranged between two adjacent straight portions; the arc-shaped bending portion is arranged between two adjacent straight portions or between one of the straight portions and the end section.

[0010] Preferably, the end section includes a head section and a tail section; the head section and the tail section are symmetrically connected to the two side ends of the bending section; and each of the bus metal sheets is provided with corresponding mounting holes at the position of the head section and the tail section.

[0011] Preferably, the protective outer body is made of polypropylene material.

[0012] Preferably, the busbar metal sheet comprises a metal body and an anti-corrosion coating connected to upper and lower surfaces of the metal body.

[0013] Preferably, the anti-corrosion coating is made of matte tin material.

[0014] Preferably, the thickness h3 of the matte tin material satisfies: 2 μm≤h3≤4 μm.

[0015] Preferably, the thickness h2 of the bus metal sheet satisfies: 0.5 mm ≤ h2 ≤ 1 mm.

[0016] Preferably, the thickness h1 of the protective outer body satisfies: 1.2 mm≤h1≤2 mm.

[0017] The beneficial effect of the present invention is that the technical solution adopts the method of exposing the multi-layer busbar metal sheets at the end sections and assembling them in a stacked manner on a protective outer body to ensure the safety and stability of the halogen-free soft busbar structure, and can improve the multi-dimensional formability and achieve the advantages of reasonable and compact structure and beautiful appearance, while achieving large current carrying capacity and better heat dissipation and insulation. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The following will refer to the attached Figures 1 to 4 To describe the features, advantages and technical effects of exemplary embodiments of the present invention.

[0019] Figure 1 A cross-sectional view of a halogen-free flexible busbar structure according to an embodiment of the present invention;

[0020] Figure 2 This is a schematic structural diagram of a halogen-free soft busbar structure after bending according to an embodiment of the present invention;

[0021] Figure 3 A partial enlarged view of a halogen-free soft busbar structure according to an embodiment of the present invention;

[0022] Figure 4 The figure is a schematic structural diagram of a collector body of a halogen-free soft busbar structure according to an embodiment of the present invention.

[0023] In the figure: 100-bending section; 101-straight section; 102-winding bending section; 103-arc-shaped bending section; 200-end section; 201-head section; 202-tail section; 1-protective outer body; 2-collector body; 21-collector metal sheet; 22-mounting hole; 23-anti-corrosion coating; 24-metal body; 3-support mechanism; 31-support surround; 32-support assembly block; 321-assembly hole. DETAILED DESCRIPTION

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which this application belongs; the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned figure descriptions and any variations thereof are intended to cover non-exclusive inclusions.

[0025] In the description of the embodiments of the present application, the technical terms "first", "second", etc. are only used to distinguish different objects, and cannot be understood as indicating or implying relative importance or implicitly indicating the number, specific order or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present application, the meaning of "multiple" is more than two, unless otherwise clearly and specifically defined.

[0026] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0027] In the description of the embodiments of the present application, the term "and / or" is only a description of the association relationship of the associated objects, indicating that there may be three relationships. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and multiple situations exist alone. In addition, the character " / " in this article generally indicates that the associated objects before and after are in an "or" relationship.

[0028] In the description of the embodiments of the present application, unless otherwise clearly specified and limited, technical terms such as "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present application can be understood according to the specific circumstances.

[0029] The following is combined with Figure 1 to Figure 4 The present invention is further described in detail, but is not intended to limit the present invention.

[0030] like Figure 1 and 3 As shown, in one embodiment of the present invention, the halogen-free soft busbar structure comprises a protective outer body 1 and a busbar 2; the busbar 2 comprises at least two busbar metal sheets 21 stacked in sequence; all the busbar metal sheets 21 pass through the interior of the protective outer body 1, and all the busbar metal sheets 21 are connected to the interior of the protective outer body 1; the halogen-free soft busbar structure is provided with a bending section 100 and an end section 200;

[0031] When the halogen-free flexible busbar structure is in a bent state and in the end section 200, the projection of each of the busbar metal sheets 21 toward the protective outer body 1 is at least partially overlapped or staggered with the protective outer body 1. Figure 1 , 2 As shown in FIG. 3 , the projection of each of the bus metal sheets 21 toward the protective outer body 1 is at least partially overlapped with the protective outer body 1 .

[0032] The technical solution of the present invention adopts the method of exposing the multi-layer busbar metal sheets at the end sections and assembling them in a stacked manner on a protective outer body to ensure the safety and stability of the halogen-free soft busbar structure, improve the multi-dimensional formability and achieve the advantages of reasonable and compact structure and beautiful appearance, while achieving large current carrying capacity and better heat dissipation and insulation.

[0033] Specifically, in some embodiments, Figure 1 and 2 As shown, in the bending section 100, the projection of each of the busbar metal sheets 21 toward the protective outer body 1 is overlapped with the protective outer body 1; and the outermost busbar metal sheets 21 abut against the inner wall of the protective outer body 1. That is, in the bending section 100, a compact structure is formed between all the busbar metal sheets 21 and the protective outer body 1, so as to have a good current carrying capacity. Figure 1 and 2 As shown, the bending section 100 includes at least two straight portions 101, at least one winding bending portion 102 and at least one arc-shaped bending portion 103; the winding bending portion 102 is arranged between two adjacent straight portions 101; the arc-shaped bending portion 103 is arranged between two adjacent straight portions 101 or between one of the straight portions 101 and the end section 200. Further, as Figure 2As shown, there are three straight portions 101; one winding bend portion 102; two arc-shaped bend portions 103; the winding bend portion 102 is disposed between two adjacent straight portions 101; and the arc-shaped bend portion 103 is disposed between two adjacent straight portions 101. The structure can improve multi-dimensional formability and realize a halogen-free soft busbar structure with reasonable and compact structure and beautiful appearance through the cooperation of the straight portion 101, the winding bend portion 102 and the arc-shaped bend portion 103, and has good current carrying capacity and heat dissipation performance. Further, in some embodiments, such as Figure 1 and 2 As shown, a support mechanism 3 is provided on the straight portion 101; the support mechanism 3 includes a support surround 31 and a support assembly block 32; an assembly hole 321 is provided in the support assembly block 32; one end of the support surround 31 is connected to the bottom of the support assembly block 32; the other end of the support surround 31 is arranged around the surface of the protective outer body 1, and the other end of the support surround 31 is arranged through the assembly hole 321. This structure can cover and suspend the protective outer body 1 through the support surround 31 and the support assembly block 32 of the support mechanism 3, thereby improving the convenience of assembly with external accessories.

[0034] Specifically, in some embodiments, Figure 1 and 2 As shown, the end section 200 includes a head section 201 and a tail section 202; the head section 201 and the tail section 202 are symmetrically connected to the two side ends of the bending section 100; and each of the busbar metal sheets 21 is provided with corresponding mounting holes 22 at the head section 201 and the tail section 202. This structure removes the protective outer body of the busbar body 2 at both ends of the head and tail to realize the naked display of the busbar body 2, thereby improving the convenience of assembly and the rapidity of the production process, and has the advantages of reasonable and compact structure, beautiful appearance, large current carrying capacity, etc.

[0035] Specifically, in some embodiments, the protective outer body 1 is made of polypropylene. The insulating sleeve made of polypropylene material usually achieves reliable performance in different application environments; and has excellent aging resistance, impact resistance, wear resistance, and is economical and applicable. Among them, the components of the polypropylene material include propylene-ethylene copolymer, ethylene-zinc olefin copolymer, halogen-free flame retardant and masterbatch. Further, the mass fraction A of propylene-ethylene copolymer: the mass fraction B of ethylene-zinc olefin copolymer: the mass fraction C of halogen-free flame retardant: the mass fraction D of masterbatch = (45% to 50%): (40% to 44%): (2% to 5%): (3% to 5%); and A+B+C+D≤100. That is, A+B+C+D can be 45%: 40%: 2%: 3% or 45%: 40%: 5%: 5% or 46%: 44%: 5%: 5%, etc. However, A, B, C, and D cannot take values ​​whose sum exceeds 100%. That is to say, the polypropylene material formed by a certain appropriate ratio can meet the halogen-free requirements determined by the EN14582:2016 method. The IC is used for analysis to detect that the fluorine is ≤20ppm, and the chlorine, bromine, and iodine are all ≤50ppm. In addition, the polypropylene material formed by the component obtains a halogen-free soft busbar; thereby achieving large current carrying capacity, heat dissipation, insulation, and excellent halogen-free environmental protection performance. Further, the preparation process of the insulating sleeve of the polypropylene material is: first, the same proportion of propylene-ethylene copolymer and ethylene-zinc olefin copolymer are mixed to form a mixture, and then the same proportion of halogen flame retardant and masterbatch are added to the mixture, and halogen-free particles are made by extrusion and pelletization; thereby forming an insulating sleeve of the polypropylene material. The halogen flame retardant can be one of a metal hydroxide, a boron-containing compound, an intumescent flame retardant, a phosphorus-based flame retardant, and a silicon-based flame retardant. The metal hydroxide, the boron-containing compound, the intumescent flame retardant, the phosphorus-based flame retardant, and the silicon-based flame retardant can be one of a PE masterbatch, a PP masterbatch, an ABS masterbatch, a PVC masterbatch, and an EVA masterbatch.

[0036] Specifically, in some embodiments, Figure 3 and 4 As shown, the busbar metal sheet 21 includes a metal body 24 and an anti-corrosion coating 23 connected to the upper and lower surfaces of the metal body 24. In some embodiments, the metal body 24 is a copper structure; the anti-corrosion coating 23 is a matte tin material. Matte tin material has the characteristics of easy welding and good conductivity, and can effectively protect copper materials from oxidation, thereby achieving better conductivity and anti-corrosion effects, and enhancing the anti-corrosion ability and welding performance of the busbar.

[0037] Further, in some embodiments, Figure 4As shown, the anti-corrosion coating 23 is made of matte tin material; and the thickness h3 of the matte tin material satisfies: 2μm≤h3≤4μm. Among them, h3 can be 2μm, 2.5μm, 2.8μm, 3μm, 3.5μm, 4μm, etc. Matte tin material is a coating with good solderability and certain corrosiveness. Therefore, this structure can ensure the corrosion resistance of the lap joint.

[0038] Further, in some embodiments, Figure 4 As shown, the relationship between the thickness h3 of the matte tin material and the thickness h4 of the metal body 24 satisfies: h3 = (1 / 3 to 1 / 2) * h4. Preferably, h3 = 1 / 3 * h4. This structure can ensure the overall structural stability and also enhance the anti-corrosion ability and welding performance of the busbar.

[0039] Specifically, in some embodiments, Figure 1 , 2 As shown in FIG. 3 , the thickness h1 of the protective outer body 1 satisfies: 1.2 mm ≤ h1 ≤ 2 mm. Among them, h1 can be 1.2 mm, 1.3 mm, 1.5 mm, 1.7 mm, 1.9 mm, 1.95 mm, 2 mm, etc. This structure can meet the insulation withstand voltage requirements; improve the compactness of the structure; and ensure the stability of its own structure and improve the reasonable and compact performance of the structure.

[0040] Specifically, in some embodiments, Figure 1 and 3 As shown, the number of the busbar metal sheets 21 is 2 to 10; and all the busbar metal sheets 21 are closely arranged inside the protective outer body 1. That is to say, the copper structure is usually composed of 2 to 10 layers stacked inside the protective outer body 1; to increase the current carrying capacity as much as possible; and to ensure the stability of its own structure and improve the reasonable and compact performance of the structure. Figure 3 and 4 As shown, the thickness h2 of the busbar metal sheet 21 satisfies: 0.5mm≤h2≤1mm. h2 can be 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1.0mm, etc.; preferably 0.5mm or 1mm. In other words, the single layer of the copper structure is 0.5mm or 1mm, usually stacked by 2-10 layers; to achieve better heat dissipation, current carrying capacity, and flexibility, and to increase the current carrying capacity as much as possible; it can also ensure the stability of its own structure and improve the reasonable and compact performance of the structure.

[0041] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode includes only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

[0042] According to the disclosure and teaching of the above description, those skilled in the art to which the present invention belongs can also change and modify the above embodiment. Therefore, the present invention is not limited to the above specific embodiment, and any obvious improvement, replacement or modification made by those skilled in the art on the basis of the present invention belongs to the protection scope of the present invention. In addition, although some specific terms are used in this specification, these terms are only for the convenience of description and do not constitute any limitation to the present invention.

Claims

1. A halogen-free soft busbar structure, characterized in that: It comprises a protective outer body and a busbar; the busbar comprises at least two stacked busbar metal sheets; all the busbar metal sheets pass through the interior of the protective outer body, and all the busbar metal sheets are connected to the interior of the protective outer body; the halogen-free soft busbar structure is provided with a bending section and an end section; When the halogen-free flexible busbar structure is in a bent state and in the end section, a projection of each of the busbar metal sheets toward the protective outer body is at least partially overlapped or staggered with the protective outer body.

2. The halogen-free flexible busbar structure according to claim 1, characterized in that: In the bending section, a projection of each of the busbar metal sheets toward the protective outer body is arranged to overlap with the protective outer body; and the outermost busbar metal sheets abut against the inner wall of the protective outer body.

3. The halogen-free flexible busbar structure according to claim 1 or 2, characterized in that: The bending section includes at least two straight portions, at least one winding bending portion and at least one arc-shaped bending portion; the winding bending portion is arranged between two adjacent straight portions; the arc-shaped bending portion is arranged between two adjacent straight portions or between one of the straight portions and the end section.

4. The halogen-free flexible busbar structure according to claim 1, characterized in that: The end section includes a head section and a tail section; the head section and the tail section are relatively connected to the two side ends of the bending section; and each of the busbar metal sheets is provided with corresponding mounting holes at the positions of the head section and the tail section.

5. The halogen-free flexible busbar structure according to claim 1, characterized in that: The protective outer body is made of polypropylene material.

6. The halogen-free flexible busbar structure according to claim 1, characterized in that: The busbar metal sheet comprises a metal body and an anti-corrosion coating connected to upper and lower surfaces of the metal body.

7. The halogen-free flexible busbar structure according to claim 6, characterized in that: The anti-corrosion coating is made of matte tin material.

8. The halogen-free flexible busbar structure according to claim 7, characterized in that: The thickness h3 of the matte tin material satisfies: 2 μm≤h3≤4 μm.

9. The halogen-free flexible busbar structure according to claim 1 or 6, characterized in that: The thickness h2 of the bus metal sheet satisfies: 0.5 mm ≤ h2 ≤ 1 mm.

10. The halogen-free flexible busbar structure according to claim 1, characterized in that: The thickness h1 of the protective outer body satisfies: 1.2 mm≤h1≤2 mm.

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