Busbar and processing technology thereof

Abstract

The invention relates to the technical field of power transmission, and particularly discloses a busbar and a processing technology thereof, and the busbar comprises an insulating sleeve and a copper bar group. The insulating sleeve comprises an inner insulating layer, a braid layer and an outer insulating layer, the braid layer wraps the inner insulating layer, and the outer insulating layer wraps the braid layer; the inner insulating layer is provided with a mounting channel; the braid layer is formed by obliquely staggering aramid yarn warp yarns and aramid yarn weft yarns on the periphery of the inner insulating layer; the copper bar group comprises a plurality of strip-shaped copper bars, and the plurality of strip-shaped copper bars are stacked in sequence; and the copper bar group can be inserted into the mounting channel. According to the invention, the copper bar group is mounted in the insulating sleeve in an inserted manner, and both the copper bar group and the insulating sleeve can be bent in the process without influencing the dimensional precision of the busbar or causing uneven deformation and damage on the surface of the busbar, so that the mounting time is shortened, the maintenance requirement is lowered, and the energy efficiency is improved; and the long-term cost can be obviously saved.

Description

Technical Field

[0001] The present invention relates to the technical field of power transmission, and in particular to a busbar and its processing technology. Background Art

[0002] A busbar is a metal conductor, and its main function is to effectively conduct electric power from a power source to various electrical loads. It is not only an important connection point of electrical equipment, such as circuit breakers, fuses, switches, etc., but also can be directly installed or connected to these components by bolts, clips or other means. The busbar provides a low-resistance path for the current, thereby reducing power loss and ensuring the efficiency of power transmission. In some scenarios, the busbar is also responsible for establishing a stable electrical connection between different components to regulate the voltage within the system.

[0003] In the prior art, a heat shrinkable tube is sleeved outside the copper bar, and is shaped by baking and shrinking with a heat gun. However, in this process, it is easy to have uneven heating, resulting in an uneven surface of the busbar or the size not meeting the requirements after shrinking. Moreover, during the installation of the heat shrinkable tube, the busbar may be deformed due to mechanical vibration, temperature change or external pressure, resulting in deformation of the heat shrinkable tube and even cracking problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a busbar and its processing technology to solve the problems in the prior art that when using a heat shrinkable tube to shrink and shape outside the copper bar, the surface of the busbar is uneven or the size does not meet the requirements after shrinking, and during the installation of the heat shrinkable tube, the busbar may be deformed due to mechanical vibration, temperature change or external pressure, resulting in deformation of the heat shrinkable tube and even cracking problems.

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

[0006] On the one hand, the present invention provides a busbar, including:

[0007] An insulating sleeve, the insulating sleeve includes an inner insulating layer, a braided layer and an outer insulating layer. The braided layer is coated outside the inner insulating layer, and the outer insulating layer is coated outside the braided layer; the inner insulating layer has an installation channel, and the installation channel penetrates through both ends of the inner insulating layer along the length direction of the inner insulating layer; the braided layer is formed by the diagonal intersection of aramid warp yarns and aramid weft yarns on the outer periphery of the inner insulating layer;

[0008] A copper bar group, the copper bar group includes several strip-shaped copper bars, and several strip-shaped copper bars are stacked in sequence; the copper bar group can be inserted into the installation channel.

[0009] As an optional solution of the above busbar, the cross-sectional dimension of the installation channel is larger than the cross-sectional dimension of the copper bar group.

[0010] As an optional solution for the above-mentioned busbar, the inner wall of the installation channel is protrudingly provided with a plurality of first protrusions, and the plurality of first protrusions are arranged at intervals to form a first frosted layer.

[0011] As an optional solution for the above-mentioned busbar, the installation channel and the copper busbar group are both rectangular structures; the first frosted layer is arranged on opposite sides of the installation channel and contacts the top surface and the bottom surface of the copper busbar group respectively.

[0012] As an optional solution for the above-mentioned busbar, the outer wall of the outer insulating layer is protrudingly provided with a plurality of second protrusions, and the plurality of second protrusions are arranged at intervals to form a second frosted layer.

[0013] As an optional solution for the above busbar, the outer insulating layer is a rectangular structure, and the second frosted layer is arranged on two opposite sides of the outer insulating layer close to the side of the copper busbar group.

[0014] As an optional solution for the above-mentioned busbar, a tin layer is formed on the outside of the strip copper busbar by electroplating.

[0015] On the other hand, the present invention provides a processing technology for a busbar, which is used to process the busbar into the above-mentioned busbar, and the processing technology for the busbar comprises the following steps:

[0016] Extruding the insulating material through an extruder to form an inner insulating layer, and applying pressure during extrusion so that a first frosted layer is formed on the inner wall of the inner insulating layer;

[0017] A braided layer is formed on the outer periphery of the inner insulating layer by obliquely interlacing aramid yarns and aramid yarns;

[0018] The insulating material is squeezed onto the outer periphery of the braided layer by the extruder to form an outer insulating layer, and the outer wall of the outer insulating layer is subjected to pressure during extrusion so as to form a second frosted layer;

[0019] The copper material is extruded into a plurality of strip-shaped copper bars by an extruder, and the plurality of strip-shaped copper bars are stacked in sequence and inserted into the installation channel of the inner insulating layer.

[0020] As an optional solution for the processing technology of the above-mentioned busbar, after the insulating material is extruded by an extruder to form an inner insulating layer, it also includes: sequentially performing negative pressure air cooling treatment and water cooling treatment on the inner insulating layer.

[0021] As an optional scheme for the processing technology of the above-mentioned busbar, after the copper material is extruded by an extruder to form a plurality of strip copper bars, and before the plurality of strip copper bars are stacked in sequence and inserted into the installation channel of the inner insulation layer, it also includes: tinning and washing the outer surface of the strip copper bar.

[0022] The beneficial effects of the present invention are as follows:

[0023] The busbar includes an insulating sleeve and a copper bar group. The insulating sleeve includes an inner insulating layer, a braided layer, and an outer insulating layer. The braided layer is coated outside the inner insulating layer, and the outer insulating layer is coated outside the braided layer. Thus, the inner insulating layer, the braided layer, and the outer insulating layer can be combined to form the insulating sleeve. The braided layer is formed by the diagonal intersection of aramid yarn warp and aramid yarn weft on the outer periphery of the inner insulating layer. Thus, through the setting of the braided layer, the overall strength and elongation rate of the insulating sleeve can be improved, facilitating large-angle bending or even folding in half, preventing damage, and the inner insulating layer and the outer insulating layer can also be formed by different processes to meet the actual molding requirements. Among them, the inner insulating layer has an installation channel, and the installation channel penetrates both ends of the inner insulating layer along the length direction of the inner insulating layer. The copper bar group includes several strip-shaped copper bars, and the several strip-shaped copper bars are stacked in sequence, and the copper bar group can be inserted into the installation channel. Thus, the copper bar group is installed in the insulating sleeve by plugging. During this process, both the copper bar group and the insulating sleeve can be bent, but it will not affect the dimensional accuracy of the busbar, nor will it cause uneven deformation or damage on the surface of the busbar. Thereby, the installation time is reduced, the maintenance requirements are lowered, and the energy efficiency is improved, significantly saving long-term costs, avoiding the problem that the surface of the busbar is uneven or the size does not meet the requirements after shrinking the heat shrinkable tube outside the copper bar, and during the installation process of the heat shrinkable tube, the busbar may be deformed due to mechanical vibration, temperature change, or external pressure, resulting in deformation of the heat shrinkable tube or even rupture.

[0024] The busbar of the present invention is processed by the processing technology of the busbar as described above. The processing process flow of the busbar is simple and has high dimensional accuracy. After separately processing and forming the insulating sleeve and the copper bar group, the busbar can be obtained by assembling, avoiding the problems of low dimensional accuracy or even damage caused by shrinking the heat shrinkable tube outside the copper bar group or directly extruding the insulating molding outside the copper bar group using an extruder. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic structural diagram of the insulating sleeve provided by an embodiment of the present invention;

[0026] Figure 2 It is a schematic structural diagram of the copper bar group provided by an embodiment of the present invention;

[0027] Figure 3 It is a schematic flow diagram of the processing technology of the busbar provided by an embodiment of the present invention.

[0028] In the figure:

[0029] 1. Insulating sleeve; 11. Inner insulating layer; 111. Installation channel; 112. First matte layer; 12. Braided layer; 13. Outer insulating layer; 131. Second matte layer; 2. Copper bar group; 21. Strip-shaped copper bar. Detailed implementation mode

[0030] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0031] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions, and moreover, the first feature being "above", "over" and "on" the second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the first feature has a higher horizontal height than the second feature. The first feature being "below", "beneath" and "under" the second feature includes the first feature being directly below and obliquely below the second feature, or simply indicating that the first feature has a lower horizontal height than the second feature.

[0032] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" 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 directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0033] The embodiments of the present invention will be described in detail below. The examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention and should not be construed as a limitation of the present invention.

[0034] Embodiment 1

[0035] As Figure 1 and Figure 2 shown, this embodiment provides a busbar that can achieve effective conduction of electricity.

[0036] The busbar includes an insulating sleeve 1 and a copper bar group 2. The insulating sleeve 1 includes an inner insulating layer 11, a braided layer 12, and an outer insulating layer 13. The braided layer 12 is coated outside the inner insulating layer 11, and the outer insulating layer 13 is coated outside the braided layer 12. Thus, the inner insulating layer 11, the braided layer 12, and the outer insulating layer 13 can be combined to form the insulating sleeve 1. The braided layer 12 is formed by the diagonal intersection of aramid fiber warp yarns and aramid fiber weft yarns on the outer periphery of the inner insulating layer 11. Thus, through the setting of the braided layer 12, the overall strength and elongation rate of the insulating sleeve 1 can be improved, facilitating large-angle bending, even folding in half, preventing damage, and the inner insulating layer 11 and the outer insulating layer 13 can also be formed by different processes to meet the actual forming requirements.

[0037] Among them, the inner insulating layer 11 has an installation channel 111. The installation channel 111 runs through both ends of the inner insulating layer 11 along the length direction of the inner insulating layer 11. The copper bar group 2 includes a plurality of strip-shaped copper bars 21. The plurality of strip-shaped copper bars 21 are stacked in sequence, and the copper bar group 2 can be inserted into the installation channel 111. Thus, the copper bar group 2 is installed in the insulating sleeve 1 by plugging. During this process, both the copper bar group 2 and the insulating sleeve 1 can be bent, but it will not affect the dimensional accuracy of the busbar, nor will it cause deformation and damage with a highly uneven surface on the busbar. Thereby, the installation time is reduced, the maintenance requirements are lowered, and the energy efficiency is improved, significantly saving long-term costs. It avoids the problem that after using a heat shrinkable tube for shrinking and shaping outside the copper bar, the surface of the busbar is uneven or the size after shrinking does not meet the requirements, and during the installation process of the heat shrinkable tube, the busbar may be deformed due to mechanical vibration, temperature change, or external pressure, resulting in deformation of the heat shrinkable tube and even rupture.

[0038] The copper bar group 2 is formed by stacking a plurality of strip-shaped copper bars 21 in sequence. Thus, the overall busbar is softer after formation, capable of large-angle bending, even folding in half, and the number of strip-shaped copper bars 21 can be increased or decreased according to the required size of the insulating sleeve 1. Thereby, the high-efficiency, reliable, and flexible characteristics of the busbar are improved, meeting the requirements in actual working conditions. Optionally, a tin layer is electroplated on the outside of the strip-shaped copper bar 21, thereby preventing the surface of the strip-shaped copper bar 21 from being oxidized or corroded and affecting the normal use of the busbar. Further optionally, the inner insulating layer 11, the braided layer 12, and the outer insulating layer 13 are all made of low-smoke and halogen-free materials.

[0039] Further, the cross-sectional dimension of the installation channel 111 is larger than that of the copper busbar group 2, so that a gap is formed between the inner wall of the installation channel 111 and the copper busbar group 2, which makes it more convenient to install the copper busbar group 2 in the insulating sleeve 1. Moreover, the flexibility of the overall busbar is further improved, facilitating large-angle bending and folding of the busbar. Among them, several first protrusions are convexly arranged on the inner wall of the installation channel 111, and the several first protrusions are arranged at intervals to form a first abrasive layer 112. Through the setting of the first abrasive layer 112, the friction force with the copper busbar group 2 can be increased, thereby preventing the copper busbar group 2 from sliding relative to the insulating sleeve 1 and causing detachment. Optionally, both the installation channel 111 and the copper busbar group 2 are rectangular structures, and the first abrasive layer 112 is arranged on the opposite sides of the installation channel 111 and is in contact with the top surface and the bottom surface of the copper busbar group 2 respectively, so that the first abrasive layer 112 can directly contact the surface of the outermost strip-shaped copper busbar 21 in the copper busbar group 2, thereby increasing the friction force with the copper busbar group 2.

[0040] Further, several second protrusions are convexly arranged on the outer wall of the outer insulating layer 13, and the several second protrusions are arranged at intervals to form a second abrasive layer 131. Through the setting of the second abrasive layer 131, it is convenient for the staff to grasp and carry the busbar, avoiding the busbar from slipping off. Optionally, the outer insulating layer 13 is a rectangular structure, and the second abrasive layer 131 is arranged on the opposite sides of the outer insulating layer 13 close to the side of the copper busbar group 2. Thus, after the busbar is bent at a large angle to form a coil, the second abrasive layer 131 is located on both sides of the coil, which can prevent the coil from sliding during transportation, thereby improving the transportation safety.

[0041] Embodiment 2

[0042] This embodiment also provides a processing technology for the busbar, which is used to process the busbar as in Embodiment 1.

[0043] As Figure 3 shown, the processing technology of the busbar includes the following steps:

[0044] The insulating material is extruded by an extruder to form the inner insulating layer 11, and at the same time, under the pressure during extrusion, the inner wall of the inner insulating layer 11 forms the first abrasive layer 112;

[0045] The aramid warp yarns and aramid weft yarns are obliquely interwoven to form a braided layer 12 on the outer periphery of the inner insulating layer 11;

[0046] The insulating material is extruded by an extruder on the outer periphery of the braided layer 12 to form the outer insulating layer 13, and at the same time, under the pressure during extrusion, the outer wall of the outer insulating layer 13 forms the second abrasive layer 131;

[0047] The copper material is extruded by an extruder to form a plurality of strip-shaped copper bars 21 , and the plurality of strip-shaped copper bars 21 are stacked in sequence and inserted into the installation channel 111 of the inner insulating layer 11 .

[0048] The processing process of the busbar is simple and has high dimensional accuracy. After the insulating sleeve 1 and the copper busbar group 2 are processed and formed respectively, the busbar can be obtained by assembling them, thereby avoiding the problem of low dimensional accuracy or even breakage caused by shrinking the heat shrink tube to shape it outside the copper busbar group 2, or using an extruder to directly extrude the insulation molding outside the copper busbar group 2.

[0049] Furthermore, when the insulating material is extruded by an extruder to form the inner insulating layer 11, in order to facilitate the insertion of the copper bar group 2 into the inner insulating layer 11, the installation channel 111 is extruded to form a rectangular structure, and the size of the installation channel 111 is larger than the size of the copper bar group 2, so that a gap is formed between the copper bar group 2 and the inner wall of the installation channel 111, wherein the length of the narrow side of the installation channel 111 is 1.5mm to 2.0mm larger than the size of the copper bar group 2, and the length of the wide side is 0.5mm to 1mm larger than the size of the copper bar group 2. Among them, the inner insulating layer 11 is subjected to pressure during extrusion so that the inner wall of the inner insulating layer 11 forms a first frosted layer 112. The molding of this first frosted layer 112 mainly depends on the mold design. The extrusion adopts a square tube extrusion mold core, the mold core nozzle is about 3mm to 4mm long, and there are concave and convex patterns on the mold core nozzle. The extrusion pressure can form the first frosted layer 112 on the inner wall of the inner insulating layer 11.

[0050] Furthermore, after the insulating material is extruded through an extruder to form the inner insulating layer 11, the inner insulating layer 11 is subjected to negative pressure air cooling and water cooling in sequence. Since the inner insulating layer 11 is a hollow tube, under the action of gravity, the upper layer of the inner insulating layer 11 will sag and contact the lower layer. If it is not cooled and shaped, the upper and lower layers will adhere to each other, affecting the subsequent insertion of the copper busbar group 2. Therefore, negative pressure air cooling and water cooling are added after extrusion by the extruder to allow the inner insulating layer 11 to be cooled and shaped.

[0051] Furthermore, when the aramid warp yarns and aramid weft yarns are obliquely interlaced to form a braided layer 12 on the periphery of the inner insulating layer 11, the braiding angle is controlled between 50° and 60°, and the braiding density is ≥60%, so that the braided layer 12 is located between the inner insulating layer 11 and the outer insulating layer 13, thereby greatly enhancing the flexibility and shear resistance of the material.

[0052] Furthermore, when the copper material is extruded by the extruder to form a plurality of strip copper bars 21, the thickness of the strip copper bar 21 is 1.0 mm, the precision is ±0.05 mm, and the width can be controlled within 15 mm to 70 mm according to requirements, with a precision of ±0.1 mm; the strip copper bar 21 is continuously annealed during the extrusion process, so that the elongation at break of the strip copper bar 21 is ≥15%, and the strength is ≥210 MPa. At the same time, after the copper material is extruded by the extruder to form a plurality of strip copper bars 21, and before the plurality of strip copper bars 21 are stacked and inserted into the installation channel 111 of the inner insulating layer 11 in sequence, the outer surface of the strip copper bar 21 is tinned and washed with water, and the surface of the strip copper bar 21 is tinned by electroplating, wherein the copper bar is used as the cathode and the tin plate is used as the anode. After power is applied, a tin layer is evenly deposited on the surface of the strip copper bar 21, and the strip copper bar 21 is thoroughly washed with water after electroplating to avoid residual electrolyte. Optionally, the thickness of the tin layer should be no less than 2 μm, and it should be firmly adhered to the surface of the strip copper bus 21 , and no undesirable phenomena such as warping and falling off will occur after repeated bending.

[0053] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A busbar, characterized in that: include: An insulating sleeve (1), the insulating sleeve (1) comprising an inner insulating layer (11), a braided layer (12) and an outer insulating layer (13), the braided layer (12) being coated on the outside of the inner insulating layer (11), and the outer insulating layer (13) being coated on the outside of the braided layer (12); the inner insulating layer (11) having an installation channel (111), the installation channel (111) penetrating through both ends of the inner insulating layer (11) along the length direction of the inner insulating layer (11); the braided layer (12) being formed by aramid yarn warp yarns and aramid yarn weft yarns obliquely interlaced on the outer periphery of the inner insulating layer (11); A copper bar group (2), the copper bar group (2) comprising a plurality of strip-shaped copper bars (21), the plurality of strip-shaped copper bars (21) being stacked in sequence; the copper bar group (2) can be inserted into the installation channel (111).

2. The busbar according to claim 1, characterized in that: The cross-sectional dimension of the installation channel (111) is greater than the cross-sectional dimension of the copper busbar assembly (2).

3. The busbar according to claim 2, characterized in that: The inner wall of the installation channel (111) is protrudingly provided with a plurality of first protrusions, and the plurality of first protrusions are arranged at intervals to form a first frosted layer (112).

4. The busbar according to claim 3, characterized in that: The installation channel (111) and the copper bar group (2) are both rectangular structures; the first frosted layer (112) is arranged on two opposite sides of the installation channel (111) and is in contact with the top surface and the bottom surface of the copper bar group (2) respectively.

5. The busbar according to claim 1, characterized in that: The outer wall of the outer insulating layer (13) is protrudingly provided with a plurality of second protrusions, and the plurality of second protrusions are arranged at intervals to form a second frosted layer (131).

6. The busbar according to claim 5, characterized in that: The outer insulating layer (13) is a rectangular structure, and the second frosted layer (131) is arranged on two opposite sides of the outer insulating layer (13) close to the side of the copper bar group (2).

7. The busbar according to any one of claims 1 to 6, characterized in that: The strip-shaped copper busbar (21) is electroplated to form a tin layer on the outside.

8. A processing technology for a busbar, characterized in that: Used to be processed into the busbar according to any one of claims 1 to 7, the processing technology of the busbar comprises the following steps: Extruding the insulating material through an extruder to form an inner insulating layer (11), and at the same time applying pressure during extrusion so that the inner wall of the inner insulating layer (11) forms a first frosted layer (112); A braided layer (12) is formed on the outer periphery of the inner insulating layer (11) by obliquely interlacing aramid yarns and aramid yarns; The insulating material is squeezed onto the outer periphery of the braided layer (12) by the extruder to form an outer insulating layer (13), and at the same time, the outer wall of the outer insulating layer (13) is subjected to pressure during extrusion so as to form a second frosted layer (131); A copper material is extruded by an extruder to form a plurality of strip-shaped copper bars (21), and the plurality of strip-shaped copper bars (21) are stacked in sequence and inserted into the installation channel (111) of the inner insulating layer (11).

9. The processing technology of the busbar according to claim 8, characterized in that: After the insulating material is extruded by an extruder to form an inner insulating layer (11), the method further comprises: sequentially subjecting the inner insulating layer (11) to negative pressure air cooling treatment and water cooling treatment.

10. The processing technology of the busbar according to claim 8, characterized in that: After the copper material is extruded into a plurality of strip copper bars (21) by an extruder, and before the plurality of strip copper bars (21) are stacked in sequence and inserted into the installation channel (111) of the inner insulating layer (11), the method further comprises: tinning and washing the outer surface of the strip copper bars (21).

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