High-temperature-resistant insulating busbar processing technology and high-temperature-resistant insulating busbar

Abstract

The invention relates to the technical field of busbars, in particular to a high-temperature-resistant insulating busbar processing technology and a high-temperature-resistant insulating busbar. The high-temperature-resistant insulating busbar processing technology comprises the following steps: S1, preparing a busbar base material; s2, performing extrusion molding of ceramic silica gel on the surface of the busbar conductor by adopting an extrusion tube type, semi-extrusion tube type or extrusion type extrusion mode; s3, winding a glass fabric or a polyimide film on the surface of the ceramic silica gel layer; s4, extruding a polyamide insulating layer on the busbar of the glass fabric or the polyimide film; s5, performing high-temperature resistance test and insulation and voltage resistance test on the processed finished busbar; the high-temperature-resistant insulating busbar comprises a busbar conductor, the outer surface of the busbar conductor is coated with ceramic silica gel, the outer surface of the ceramic silica gel is coated with glass fabric or a polyimide film, and the outer surface of the glass fabric or the polyimide film is coated with a polyamide insulating layer. Through innovative material combination and process optimization, the high-temperature-resistant insulating busbar which can stably run in a high-temperature environment for a long time is prepared.

Description

Technical Field

[0001] The present invention relates to the technical field of busbars, and in particular to a high-temperature resistant insulating busbar processing technology and a high-temperature resistant insulating busbar. Background Art

[0002] Busbars are a type of conductive metal material widely used in power distribution systems, primarily used to conduct electricity from power sources to various loads. Primarily made of copper and aluminum, they possess high conductivity and corrosion resistance. While traditional mica wrapping processes offer a certain degree of high-temperature resistance, they can decompose structurally and degrade insulation performance in environments above 800°C, making them difficult to meet the demands of extreme high-temperature conditions of 1000±50°C. Furthermore, the mica sheets often lack a tight fit, creating gaps. In complex environments such as high temperature and high humidity, these gaps can easily lead to moisture intrusion and dust accumulation, compromising insulation performance and even causing short circuits. Mica is brittle, and when subjected to mechanical vibration, thermal expansion, and contraction, the mica layer can crack and fall off, compromising the overall structural stability of the busbar. Furthermore, in environments with high humidity, strong acids, and alkalis, the insulation and physical properties of mica are significantly affected, limiting the busbar's application scenarios.

[0003] Currently, some busbars use standard polyamide (PA) insulation. While PA offers reasonable insulation and mechanical strength, its molecular chains are susceptible to thermal degradation in high-temperature environments, significantly reducing the material's mechanical and insulation properties. This makes it unable to meet the demands of long-term operation under high-temperature conditions. Furthermore, some busbars use standard silicone insulation, which has limited high-temperature resistance. In high-temperature environments, its physical and chemical properties change, such as increased hardness and decreased elasticity, leading to cracking and peeling, rendering the busbar insulation ineffective and posing a significant safety hazard. Some busbars also employ a composite insulation process, simply stacking multiple insulation materials. However, this approach suffers from poor compatibility and weak interfacial bonding between the different materials. This leads to delamination under temperature fluctuations, mechanical vibration, and other factors, compromising the overall insulation performance and stability of the busbar. These issues arise, in part, from the inherent performance limitations of existing materials, which prevent them from maintaining stable physical and chemical properties over long periods of time in high-temperature environments. Furthermore, traditional manufacturing processes lack a thorough understanding of the material properties and the busbar's operating environment, resulting in deficiencies in process parameter control and material bonding. When trying to solve these problems, we face many difficulties. For example, it is difficult to find new materials with excellent high-temperature resistance and insulation properties. The process of combining new materials with the busbar matrix is ​​complex and costly. Improving existing processes requires large-scale adjustments to production equipment and process flows, which is not only time-consuming and labor-intensive, but also carries risks such as instability of the new process and low yield.

[0004] In the prior art, Chinese patent application number 202411698435.8 discloses a high-voltage busbar comprising a core busbar with a composite layer, a pressure-resistant layer, and a wear-resistant layer disposed on the outside of the core busbar. The composite layer is plastic-coated on the outside of the core busbar to improve the busbar's insulation, high-temperature resistance, and flame retardancy. The pressure-resistant layer is fixed between the composite layer and the wear-resistant layer to increase the busbar's compressive strength. The composite layer is made of a mixture of ceramic silicone and mica powder; the pressure-resistant layer is made of PI or mica paper; and the wear-resistant layer is made of TPU. This busbar core busbar is coated with the composite layer, pressure-resistant layer, and wear-resistant layer, meeting the busbar's high-voltage, insulation, pressure-resistant, and wear-resistant requirements. However, the TPU material may experience performance degradation in high-temperature environments, such as increased hardness, decreased elasticity, and even decomposition or aging. Furthermore, TPU is more expensive than some traditional wear-resistant materials, and using TPU as a wear-resistant layer may increase overall manufacturing costs, affecting the product's market competitiveness. Summary of the Invention

[0005] The purpose of the present invention is to solve the technical problems that high-temperature resistant insulating busbars on the market generally have material performance failure, insulation layer shedding or high costs after being achieved by other means when facing an extreme high temperature environment of 1000°±50°, and cannot meet the current market technology and cost application requirements. A high-temperature resistant insulating busbar processing technology and a high-temperature resistant insulating busbar are provided. Through innovative material combination and process optimization, a high-temperature resistant insulating busbar that can operate stably for a long time in a high temperature environment of 1000°±50° is prepared.

[0006] The technical solution adopted by the present invention to achieve the above-mentioned purpose is: a high-temperature resistant insulating busbar processing process, comprising the following steps:

[0007] S1: Prepare the busbar substrate and fix it to the discharge end of the extrusion equipment;

[0008] S2: Adjust the extrusion equipment so that the screw length-diameter ratio is 25:1 and the compression ratio is controlled between 1.5:1 and 2.5:1. Start the extrusion equipment according to the set parameters, add the ceramic silicone raw material into the hopper, and extrude the ceramic silicone on the surface of the busbar conductor using a tube extrusion, semi-tube extrusion, or extrusion method.

[0009] S3: After the ceramic silicone extrusion is completed, immediately wrap the glass fiber cloth or polyimide film on the surface of the ceramic silicone layer to ensure that the wrapping is tight and wrinkle-free;

[0010] S4: Add the polyamide insulation material to the extrusion equipment hopper again, keep the extrusion equipment parameters unchanged, and extrude the polyamide insulation layer on the busbar wrapped with glass fiber cloth or polyimide film through the same extrusion method;

[0011] S5: The finished busbars were subjected to high temperature resistance and insulation voltage resistance tests. The results showed that the busbars had good high temperature resistance and insulation voltage resistance, meeting the technical requirements.

[0012] Furthermore, in step S2, the compression ratio of the extrusion equipment is adjusted to 1.8:1, and ceramic silicone is extruded on the surface of the busbar conductor using a tube extrusion method.

[0013] Furthermore, in step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and a semi-extrusion tube extrusion method is adopted to extrude ceramic silicone on the surface of the busbar conductor.

[0014] Furthermore, in step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and ceramic silicone is extruded on the surface of the busbar conductor using an extrusion method.

[0015] Furthermore, in step S2, during the process of extruding ceramic silicone on the surface of the busbar conductor, the thickness of the ceramic silicone on one side is monitored and controlled in real time to be between 0.35 and 0.45 mm.

[0016] Furthermore, in step S4, during the process of extruding the polyamide insulation layer on the busbar wrapped with the glass fiber cloth or polyimide film, the thickness of the polyamide on one side is monitored and controlled in real time to be between 0.55-0.65 mm.

[0017] Furthermore, in step S5, the high temperature resistance test and the insulation withstand voltage test include the following steps: selecting some finished busbars, bending the busbars 90 degrees to simulate the bending conditions in actual use, and the test method is based on the GB / T31838.7 standard. The test is performed at a high temperature of 1000°C, the flame height is controlled to 20±1mm, and the Bunsen burner is placed in the center below the product. The Bunsen burner tube mouth is 10±1mm away from the lower end of the product. The ignition time is continued for 10 minutes and then removed. After cooling, the busbar is subjected to an insulation withstand voltage test.

[0018] Furthermore, the insulation withstand voltage test requirements are as follows:

[0019] a. Hi-pot test: Apply DC 4250V voltage, maintain for 60s, and require leakage current ≤ 0.1mA;

[0020] b. Insulation resistance test: Apply DC 1000V voltage and maintain for 60s. The insulation resistance must be ≥500MΩ.

[0021] Another technical solution adopted by the present invention to achieve the above-mentioned purpose is: a high-temperature resistant insulating busbar, including a busbar conductor, the outer surface of the busbar conductor is covered with ceramic silicone, the outer surface of the ceramic silicone is covered with glass fiber cloth or polyimide film, and the outer surface of the glass fiber cloth or polyimide film is covered with a polyamide insulation layer.

[0022] Furthermore, the ceramic silicone is extruded on the outer surface of the busbar conductor, the glass fiber cloth or polyimide film is wound on the outer surface of the ceramic silicone, and the polyamide insulation layer is extruded on the outer surface of the glass fiber cloth or polyimide film.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] (1) The present invention provides a high-temperature resistant insulating busbar processing technology. A screw with a length-to-diameter ratio of 25:1 is the best choice. This length-to-diameter ratio can fully plasticize the plastic in the screw, ensuring the stability of the extrusion process and the consistency of product quality. The compression ratio is controlled between 1.5:1 and 2.5:1, which helps to improve the density and extrusion pressure of the plastic, making the extruded insulation layer more uniform and dense, thereby improving product performance. The extrusion method adopts a tube extrusion type, a semi-tube extrusion type or an extrusion type extrusion method, which can be selected according to actual production needs and product characteristics to ensure that the insulation layer can fit closely to the busbar surface and ensure processing quality.

[0025] (2) The present invention provides a high-temperature resistant insulating busbar processing technology, which adopts an extrusion process to enable the ceramic silicone and PA insulating layers to be evenly and tightly coated on the busbar, thereby forming a continuous and defect-free insulating layer, greatly improving the sealing and integrity of the insulating layer, effectively reducing the incidence of electrical faults such as leakage and short circuit, ensuring safe and stable power transmission, and significantly increasing insulation reliability. At the same time, it can realize automated and continuous production, the processing technology is efficient and agile, and the process parameters are easy to accurately control, which can greatly improve production efficiency and product consistency, reduce production costs, and reduce the impact of human factors on product quality, making it more suitable for large-scale industrial production.

[0026] (3) The present invention provides a high-temperature resistant insulating busbar. Through the composite process of PA and ceramic silicone, the ceramic silicone will form a dense ceramic structure at high temperature. Combined with the high-temperature stability of the PA material, the busbar can stably withstand a high temperature of 1000±50° for a long time, effectively expanding the application temperature range of the busbar, and is suitable for high-precision and high-temperature fields such as aerospace and metallurgy.

[0027] (4) The present invention provides a high-temperature resistant insulating busbar. The PA material has good mechanical strength and toughness. After being combined with ceramic silicone, it can effectively buffer external stress and enhance the vibration resistance and deformation resistance of the busbar structure. Even in a harsh environment where high temperature and mechanical vibration coexist, the busbar structure can still be kept intact, thereby extending its service life.

[0028] (5) The present invention provides a high-temperature resistant insulating busbar. Both ceramic silica gel and PA materials have good chemical stability and environmental adaptability, which makes the busbar not only resistant to high temperatures, but also able to maintain stable performance in complex environments such as high humidity and corrosive gases, thereby expanding the application range of the busbar and meeting diversified industrial needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a structural diagram of the high-temperature resistant insulating busbar of the present invention.

[0030] Figure 2 This is a structural cross-sectional view of the high-temperature resistant insulating busbar of the present invention.

[0031] In the figure: 1. Busbar conductor, 2. Ceramic silicone, 3. Fiberglass cloth or polyimide film, 4. Polyamide insulation layer. DETAILED DESCRIPTION

[0032] The present invention will be described in detail below with reference to the accompanying drawings and embodiments, but the present invention is not limited to the specific embodiments.

[0033] Example 1

[0034] The present invention provides a high-temperature resistant insulating busbar processing process, comprising the following steps:

[0035] S1: Prepare the busbar substrate and fix it to the discharge end of the extrusion equipment;

[0036] S2: Start the extrusion equipment according to the set parameters, add the ceramic silicone raw material to the hopper, adjust the equipment so that the screw length-diameter ratio is 25:1 and the compression ratio is 1.8:1, and use a tube extrusion method to extrude ceramic silicone 2 onto the surface of the busbar conductor 1. Monitor and control the thickness of each side between 0.35 and 0.45 mm in real time. Ceramic silicone has excellent high-temperature resistance and insulation properties, and can form a stable protective layer in high-temperature environments, providing initial high-temperature resistance and insulation protection for the busbar.

[0037] S3: After the ceramic silicone is extruded, immediately wrap glass fiber cloth or polyimide film (PI film) around the surface of the ceramic silicone layer to ensure that the wrapping is tight and wrinkle-free. Glass fiber cloth has high strength, high temperature resistance, and good insulation properties. It further enhances the mechanical strength and high temperature resistance of the busbar, while also protecting and reinforcing the ceramic silicone layer.

[0038] S4: Add polyamide (PA) insulation material to the extrusion equipment hopper again, keep the screw aspect ratio and compression ratio unchanged, and use the same tube extrusion method to extrude the PA insulation layer on the surface of the busbar wrapped with fiberglass cloth or PI film. Control the single-side thickness between 0.55-0.65mm. The PA insulation layer has excellent electrical insulation and good mechanical properties, can effectively isolate the external electric field, and ensure the insulation safety of the busbar;

[0039] S5: The finished busbars were subjected to high temperature resistance and insulation voltage resistance tests. The results showed that the busbars had good high temperature resistance and insulation voltage resistance, meeting the technical requirements.

[0040] The high-temperature performance test and insulation withstand voltage test include the following steps: Select some finished busbars and bend them 90 degrees to simulate the bending conditions in actual use. The test method is based on the GB / T31838.7 standard. The test is conducted at a high temperature of 1000°C. The flame height is controlled at 20±1mm. A Bunsen burner is placed at the center below the product, with the burner nozzle 10±1mm from the bottom of the product. The ignition is continued for 10 minutes and then removed. After cooling, the busbar is subjected to an insulation withstand voltage test to verify the reliability of the insulation performance in the high-temperature environment.

[0041] The insulation withstand voltage test requirements are as follows:

[0042] a. Hi-pot test: Apply DC 4250V voltage and maintain for 60s. The leakage current must be ≤0.1mA.

[0043] b. Insulation resistance test: Apply DC 1000V voltage and maintain for 60s. The insulation resistance must be ≥500MΩ.

[0044] The test results show that the busbar can withstand a high temperature of 1000°C and its insulation and voltage resistance performance meets the requirements.

[0045] Example 2

[0046] The processing technology of the high temperature resistant insulating busbar of this embodiment is basically the same as that of embodiment 1, except that:

[0047] In step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and the ceramic silicone rubber 2 is extruded on the surface of the busbar conductor 1 using a semi-extrusion tube extrusion method;

[0048] In step S4, the same semi-extrusion tube extrusion method is used to extrude the PA insulation layer on the surface of the busbar wrapped with glass fiber cloth or PI film.

[0049] Example 3

[0050] The processing technology of the high temperature resistant insulating busbar of this embodiment is basically the same as that of embodiment 1, except that:

[0051] In step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and the ceramic silicone rubber 2 is extruded on the surface of the busbar conductor 1 by an extrusion method;

[0052] In step S4, the PA insulation layer is extruded on the surface of the busbar wrapped with glass fiber cloth or PI film using the same extrusion method.

[0053] A screw with a length-to-diameter ratio of 25:1 is the best choice. This ratio allows the plastic to be fully plasticized in the screw, ensuring the stability of the extrusion process and the consistency of product quality. The compression ratio is controlled between 1.5:1 and 2.5:1, which helps to improve the density of the plastic and the extrusion pressure, making the extruded insulation layer more uniform and dense, thereby improving product performance. The extrusion method adopts tube extrusion, semi-tube extrusion or extrusion extrusion. It can be selected according to actual production needs and product characteristics to ensure that the insulation layer can closely fit the busbar surface and guarantee processing quality.

[0054] The extrusion process can make the ceramic silicone and PA insulation layer evenly and tightly wrapped on the busbar, thus forming a continuous and defect-free insulation layer, greatly improving the sealing and integrity of the insulation layer, effectively reducing the incidence of electrical faults such as leakage and short circuit, ensuring safe and stable power transmission, and significantly increasing insulation reliability. At the same time, it can realize automated and continuous production, the processing technology is efficient and agile, and the process parameters are easy to accurately control, which can greatly improve production efficiency and product consistency, reduce production costs, and reduce the impact of human factors on product quality. It is more suitable for large-scale industrial production.

[0055] Example 4

[0056] like Figure 1-2 The high-temperature resistant insulating busbar shown includes a busbar conductor 1, the outer surface of the busbar conductor 1 is covered with ceramic silicone 2, the outer surface of the ceramic silicone 2 is covered with glass fiber cloth or polyimide film 3, and the outer surface of the glass fiber cloth or polyimide film 3 is covered with a polyamide insulation layer 4.

[0057] Preferably, the ceramic silicone 2 is extruded on the outer surface of the busbar conductor 1, and the single-side thickness of the ceramic silicone 2 is 0.35 to 0.45 mm. The glass fiber cloth or polyimide film 3 is wrapped around the outer surface of the ceramic silicone 2. The polyamide insulation layer 4 is extruded on the outer surface of the glass fiber cloth or polyimide film 3, and the single-side thickness of the polyamide insulation layer 4 is 0.55 to 0.65 mm.

[0058] The high-temperature resistant insulating busbar of the present invention has significant advantages and technical effects compared with the existing high-temperature resistant insulating busbar with mica wrapped inside, which are specifically reflected in the following aspects:

[0059] 1. Significantly improved high-temperature resistance: Through the PA and ceramic silicone composite process, ceramic silicone will form a dense ceramic structure at high temperatures. Combined with the high-temperature stability of PA materials, the busbar can stably withstand high temperatures of 1000±50° for a long time, effectively expanding the application temperature range of the busbar and providing a safe and stable solution for power transmission under high-temperature conditions. It is suitable for high-precision and high-temperature fields such as aerospace and metallurgy.

[0060] 2. Better structural stability: PA material has excellent mechanical strength and toughness. When combined with ceramic silicone, it can effectively buffer external stress and enhance the vibration and deformation resistance of the busbar structure. Even in harsh environments with high temperature and mechanical vibration, the busbar structure can still remain intact, extending its service life.

[0061] 3. Better environmental adaptability: Both ceramic silicone and PA materials have good chemical stability and environmental adaptability, making the busbar not only resistant to high temperatures, but also able to maintain stable performance in complex environments such as high humidity and corrosive gases, expanding the application range of the busbar and meeting diverse industrial needs.

[0062] The above content is a further detailed description of the present invention in conjunction with the preferred technical solution, and the specific implementation of the invention cannot be limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, simple deductions and substitutions can be made without departing from the concept of the present invention, which should be considered as the scope of protection of the present invention.

Claims

1. A high temperature resistant insulating busbar processing process, characterized by: It includes the following steps: S1: Prepare the busbar substrate and fix it to the discharge end of the extrusion equipment; S2: Adjust the extrusion equipment so that the screw length-diameter ratio is 25:1 and the compression ratio is controlled between 1.5:1 and 2.5:

1. Start the extrusion equipment according to the set parameters, add the ceramic silicone raw material into the hopper, and extrude the ceramic silicone on the surface of the busbar conductor using a tube extrusion, semi-tube extrusion, or extrusion method. S3: After the ceramic silicone extrusion is completed, immediately wrap the glass fiber cloth or polyimide film on the surface of the ceramic silicone layer to ensure that the wrapping is tight and wrinkle-free; S4: Add the polyamide insulation material to the extrusion equipment hopper again, keep the extrusion equipment parameters unchanged, and extrude the polyamide insulation layer on the busbar wrapped with glass fiber cloth or polyimide film through the same extrusion method; S5: The finished busbars were subjected to high temperature resistance and insulation voltage resistance tests. The results showed that the busbars had good high temperature resistance and insulation voltage resistance, meeting the technical requirements.

2. A high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S2, the compression ratio of the extrusion equipment is adjusted to 1.8:1, and ceramic silicone is extruded on the surface of the busbar conductor using a tube extrusion method.

3. A high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and a semi-extrusion tube extrusion method is used to extrude ceramic silicone on the surface of the busbar conductor.

4. A high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S2, the compression ratio of the extrusion equipment is adjusted to 2.2:1, and ceramic silicone is extruded on the surface of the busbar conductor using an extrusion method.

5. The high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S2, during the process of extruding ceramic silicone on the surface of the busbar conductor, the thickness of the ceramic silicone on one side is monitored and controlled in real time to be between 0.35 and 0.45 mm.

6. A high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S4, during the process of extruding the polyamide insulation layer on the busbar wrapped with the glass fiber cloth or polyimide film, the thickness of the polyamide on one side is monitored and controlled in real time to be between 0.55-0.65 mm.

7. A high temperature resistant insulating busbar processing process according to claim 1, characterized in that: In step S5, the high temperature resistance test and the insulation withstand voltage test include the following steps: selecting some finished busbars, bending the busbars 90 degrees to simulate the bending conditions in actual use, and the test method is based on the GB / T31838.7 standard. The test is performed at a high temperature of 1000°C, and the flame height is controlled at 20±1mm. The Bunsen burner is placed in the center below the product, and the Bunsen burner tube mouth is 10±1mm away from the lower end of the product. The ignition time lasts for 10 minutes and then removed. After cooling, the busbar is subjected to an insulation withstand voltage test.

8. A high temperature resistant insulating busbar processing process according to claim 7, characterized in that: The insulation withstand voltage test requirements are as follows: a. Hi-pot test: Apply DC 4250V voltage, maintain for 60s, and require leakage current ≤ 0.1mA; b. Insulation resistance test: Apply DC 1000V voltage and maintain for 60s. The insulation resistance must be ≥500MΩ.

9. A high-temperature resistant insulating busbar based on the high-temperature resistant insulating busbar processing process according to any one of claims 1 to 8, characterized in that: The busbar conductor comprises a busbar conductor, the outer surface of which is covered with ceramic silica gel, the outer surface of which is covered with glass fiber cloth or polyimide film, and the outer surface of which is covered with a polyamide insulation layer.

10. The high temperature resistant insulating busbar according to claim 9, characterized in that: The ceramic silica gel is extruded on the outer surface of the busbar conductor, the glass fiber cloth or polyimide film is wound on the outer surface of the ceramic silica gel, and the polyamide insulation layer is extruded on the outer surface of the glass fiber cloth or polyimide film.

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