Bus duct liquid cooling connector and assembly method thereof

Abstract

This invention relates to the technical field of busbar cooling, and mainly discloses a busbar liquid-cooled connector and its assembly method. The busbar liquid-cooled connector includes symmetrically arranged connecting parts, and a cooling element is disposed within the connecting parts. The cooling element separates the connecting parts to form a symmetrically arranged first gap. At least one set of flow channels is formed within the cooling element. The flow channel set covers the heating area of ​​the conductor busbar fixed within the first gap on both sides, and the inlet and outlet of the flow channel set are located on the same side. This invention improves upon the problems of existing connectors having narrow compatibility, high maintenance costs, and failing to meet the requirements of modern power transmission for high heat flux density, high stability, and high compatibility.

Description

Technical Field

[0001] This invention relates to the technical field of busbar cooling, and in particular to a busbar liquid-cooled connector and its assembly method. Background Technology

[0002] With the continuous increase in power transmission capacity demands from data centers, heavy industry, and other scenarios, the heat dissipation performance and reliability of connectors in busbar trunking, as core equipment for high-current transmission, have become crucial factors restricting system upgrades. Due to concentrated contact resistance and high current density at connector mating points, localized high temperatures are easily generated. Existing technologies struggle to balance efficient heat dissipation with compatibility: natural cooling, under medium-to-high current conditions above 2500A, results in temperature rises far exceeding the national standard's 60K limit, accelerating insulation aging; air-cooling solutions rely on fan drives, posing noise pollution and failure risks, and the low air heat transfer coefficient leads to a sharp decline in cooling effectiveness at high currents; conventional liquid cooling often employs dual parallel flow channels, resulting in long heat exchange paths, significant flow resistance losses, and poor heat dissipation uniformity.

[0003] Meanwhile, existing solutions generally suffer from structural separation issues—heat dissipation, connection, and protection modules are designed independently, resulting in large size, complex installation, and easy loosening under vibration. These problems lead to narrow connector compatibility and high maintenance costs, failing to meet the demands of modern power transmission for high heat flux density, high stability, and high compatibility. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is that existing connectors have narrow compatibility and high maintenance costs, and cannot meet the requirements of modern power transmission for high heat flux density, high stability and high compatibility.

[0005] The above-mentioned technical problems are solved by the following technical solution: The present invention proposes a busbar liquid-cooled connector, which includes symmetrically arranged connectors, and a cooling component is provided in the connector. The cooling component separates the connector to form a symmetrically arranged first gap. The cooling component has at least one set of flow channels, which covers the heating area of ​​the conductor busbar fixed in the first gap on both sides, and the inlet and outlet of the flow channel are located on the same side.

[0006] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: it further includes symmetrically arranged insertion rods and protective side plates. The protective side plates are symmetrically arranged, and the connectors are symmetrically arranged between the protective side plates. A second gap is formed between the connectors on both sides. The grounding bar of the busbar is fixedly inserted into the second gap. The third gap includes a guide section and a positioning sealing section from the outside to the inside. The inner diameter of the guide section is larger than the inner diameter of the positioning sealing section, forming a stepped surface. The inner side wall of the positioning sealing section has at least one annular sealing groove. An insulating sealing ring (X321) is embedded in the annular sealing groove. The protective plate is inserted into the positioning sealing section through the guide section and is interference-fitted with the insulating sealing ring. The side wall of the positioning sealing section also has a pressure relief hole communicating with the outside of the protective side plate. A third gap is formed between the connector and the protective side plate. The protective plate of the busbar is fixedly inserted into the third gap. The insertion rod enters into one side of the protective side plate, passes through the connector and the cooling component, and exits into the other side of the protective side plate.

[0007] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: an insulating sleeve is fixedly sleeved on the outside of the plug member, and insulating blocks are also fixedly sleeved on the plug members at both ends of the insulating sleeve; the connecting member and the cooling member are sleeved on the outside of the insulating sleeve, and the protective side plate is sleeved on the outside of the insulating blocks; a fixing groove is opened on the outer wall of the protective side plate, and washers are symmetrically arranged in the fixing groove, and the washers are fixedly sleeved on the outside of the plug member; wherein, at least a part of the fixing groove communicates with the pressure relief hole, and the washers avoid the opening position of the pressure relief hole; an abutment block is fixed at one end of the plug member, and the outer wall of the washer on this side abuts against the abutment block; a square nut is threaded on the other end of the plug member, and the outer wall of the washer on this side abuts against the square nut.

[0008] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: the cooling component includes a cooling plate and a first guide pipe and a second guide pipe fixed at both ends thereon, the first guide pipe and the second guide pipe being fixed to the first end and the second end of the cooling plate respectively; the flow channel group includes a first flow channel and a second flow channel symmetrically arranged, the first end and the second end corresponding to the two ends of the first flow channel and the second flow channel; a first cooling area and a second cooling area are symmetrically arranged on the cooling plate, the two ends of the first cooling area and the second cooling area are both connected to the first end and the second end; the first flow channel and the second flow channel are respectively arranged in the first cooling area and the second cooling area, and a third flow channel is opened in the second guide pipe, the third flow channel connecting the first flow channel and the second flow channel.

[0009] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: the number of the first flow channel and the second flow channel are equal; only one set of the first flow channel and the second flow channel is provided, and the first flow channel and the second flow channel completely cover the first cooling zone and the second cooling zone respectively; or, several sets of the first flow channel and the second flow channel are provided in parallel, and the first flow channel and the second flow channel are evenly distributed in the first cooling zone and the second cooling zone respectively.

[0010] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: an inlet channel and an outlet channel are independently provided in the first guide pipe, the inlet channel is connected to the first flow channel, and the outlet channel is connected to the second flow channel; an inlet pipe and an outlet pipe are also symmetrically fixed on the first guide pipe, and the inlet pipe and the outlet pipe are respectively connected to the inlet channel and the outlet channel.

[0011] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: a heat dissipation zone is formed between the first cooling zone and the second cooling zone, and the plug members are symmetrically arranged in the heat dissipation zone.

[0012] In a preferred embodiment of the busbar trunking liquid-cooled connector of the present invention: the connector includes symmetrically arranged busbar clamps, a fourth gap is formed between the busbar clamps, and the cooling component is fixed in the fourth gap; the busbar clamps include symmetrically arranged first clamps and second clamps, the first gap is located between the first clamps and the second clamps, and conductive busbars are fixedly embedded on the inner walls of the first clamps and the second clamps within the first gap, and a single set of conductors of the conductor busbars in the busbar trunking can be inserted into the first gap.

[0013] In a preferred embodiment of the busbar liquid-cooled connector of the present invention: a baffle is provided in the fourth gap, the baffle is disposed on both sides of the cooling component and fixed to the side wall of the first clamping plate.

[0014] To address the aforementioned problems, the present invention provides the following technical solution: a method for assembling a busbar liquid-cooled connector, applicable to the aforementioned busbar liquid-cooled connector, comprising the following steps: First, pre-assembly of core components is performed; the guide pipes at both ends of the connector are fixed and sealed; after installing the inlet and outlet pipes, the flow channels are ensured to be connected; conductive busbars are embedded in the inner wall of the connector's clamping plate and firmly attached; baffles are symmetrically fixed on the side wall of the clamping plate; an insulating sleeve and insulating blocks at both ends are sequentially fitted onto the outside of the insertion rod, with a stop block fixed at one end; then, the cooling component is embedded in the gap of the connector, precisely positioned by the baffle to ensure that the cooling area corresponds to the insertion position of the conductor busbar; the insertion rod passes through one protective side plate, sequentially through the connector and the heat dissipation area of ​​the cooling component, and exits from the other side; a washer is fixed in the groove on the outer wall of the protective side plate, and a square nut is tightened at the end; then, the conductor busbar is inserted into the gap of the connector, ensuring a tight fit with the conductive busbar; the grounding busbar is inserted into the gap between the two connectors; the protective plate is inserted into the gap between the connector and the protective side plate; all components are inserted into place, completing the overall assembly.

[0015] The beneficial effects of this invention are as follows: In this invention, the cooling component precisely covers the heating area of ​​the conductor busbar through a U-shaped flow channel group that enters and exits from the same side. Single or multiple flow channels can flexibly adapt to different heat load scenarios, greatly improving heat dissipation efficiency and effectively solving the problem of temperature rise under high heat flux density. Furthermore, the connector, cooling component, and protective side plate are fixed through the insertion rod, and with the addition of insulating sleeve, stop block, and washer structure, it has both reliable insulation and vibration resistance performance. At the same time, the second and third gaps enable convenient insertion of the grounding busbar and the protection board, integrating connection, heat dissipation, and protection functions, and simplifying the structural layout.

[0016] The baffle positioning design and standardized assembly process ensure accurate and tight component installation, reducing installation and maintenance difficulties; the coordinated layout of the heat dissipation area and flow channel further optimizes the heat dissipation effect. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. Obviously, the drawings described below only relate to some embodiments of the present invention and are not intended to limit the present invention. Wherein: Figure 1 The diagram shows the layout of the flow channel assembly in the busbar liquid-cooled connector.

[0018] Figure 2 A cross-sectional view of the flow channel assembly is shown.

[0019] Figure 3 A schematic diagram of the connection between the busbar liquid-cooled connector and the conductor busbar is shown.

[0020] Figure 4 A cross-sectional view of the busbar liquid-cooled connector is shown.

[0021] Figure 5 A diagram showing the distribution of different areas on the cooling component is provided.

[0022] Figure 6 A cross-sectional view of the cooling component is shown.

[0023] Figure 7 The diagram shows the distribution of different numbers of flow channels within the cooling component.

[0024] Figure 8 A detailed structural diagram of the connector is shown.

[0025] Figure 9 A schematic diagram of the conductor bus installation is shown. Detailed Implementation

[0026] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0027] The terminology used in this invention is that which is currently widely used in the art in consideration of the function of the invention; however, these terms may vary according to the intent of those skilled in the art, precedent, or new technology in the art. Furthermore, specific terms may be chosen by the applicant, and in such cases, their detailed meanings will be described in the detailed description of the invention. Therefore, the terms used in this specification should not be construed as simple names, but rather based on their meanings and the overall description of the invention.

[0028] Reference Figures 1-9 This embodiment provides a busbar trunking liquid-cooled connector, which includes symmetrically arranged connectors 100, a cooling element 200 disposed within the connectors 100, and the cooling element 200 separating the connectors 100 to form a symmetrically arranged first gap X1.

[0029] The size of the first gap X1 is precisely matched with the thickness of the conductor busbar P, ensuring that the busbar fits tightly with the connector 100 after insertion, which not only ensures the reliability of the electrical connection, but also quickly transfers the heat generated by the busbar to the cooling component 200.

[0030] Furthermore, at least one set of flow channels 201 is provided inside the cooling component 200. The flow channel group 201 covers the heat-generating area of ​​the conductor busbar P fixed in the first gap X1 on both sides. The inlet and outlet of the flow channel group 201 are located on the same side, that is, a U-shaped circulation structure is adopted. Compared with the existing heat dissipation structure, this structure can greatly improve the heat dissipation efficiency.

[0031] Specifically, in order to verify the advantages of this U-shaped flow channel liquid cooling solution in terms of temperature rise control and heat dissipation efficiency compared with traditional natural cooling, air cooling and conventional dual parallel flow channel liquid cooling under different current conditions, the following test was conducted in this embodiment.

[0032] The comparison objects and test conditions are shown in Table 1 below: Table 1 Control group 1 Traditional natural cooling connectors (no heat dissipation structure, same specification busbar trunking) Control group 2 Traditional air-cooled connector (with axial fan installed, air outlet facing the connector, air volume 5m³ / min) Control group 3 Standard liquid-cooled connector (dual parallel flow channels, Φ8mm cross-section, refrigerant is 40% water-glycol). experimental group This solution uses a U-shaped liquid-cooled connector (single channel Φ8mm, refrigerant same as control group 3).

[0033] The test conditions were as follows: current gradient 1000A, 2500A, 3500A; ambient temperature constant 25℃, no wind; refrigerant flow rate 1.0m / s, inlet temperature 25℃; temperature rise measured according to national standards.

[0034] Further, the specific steps are as follows: connect all 4 groups of samples to 100×10mm copper busbars, fix them to the same test frame, and uniformly set the contact pressure to 50N·m.

[0035] Furthermore, the fan of control group 2 and the refrigerant systems of test group and control group 3 were started. After stabilizing for 30 minutes, different currents were applied. After the temperature rise stabilized (the change within 1 hour was ≤1K), the temperature rise of the L1 / L2 / L3 phase conductors, the temperature rise of the outer shell, and the flow resistance were recorded. Each group of operating conditions was repeated 3 times, and the average value was taken.

[0036] The specific results are shown in Table 2 below: Table 2 Control group 1 1000 28.5 27.2 26.8 21.5 - - Control group 2 1000 18.3 17.5 17.1 14.2 - 35.8% Control group 3 1000 12.8 12.1 11.9 8.5 1020 55.1% experimental group 1000 11.2 10.8 10.5 7.2 850 60.0% Control group 1 2500 59.0 56.8 52.8 43.75 - - experimental group 2500 19.6 20.0 16.4 10.55 920 76.1% Control group 1 3500 82.3 79.5 76.2 65.8 - - experimental group 3500 32.9 33.8 27.5 17.8 1150 61.2%

[0037] It should be noted that some blank spaces in Table 2 are because the group does not have a liquid cooling system and therefore does not have this test index. Only groups with liquid cooling channels and refrigerant circulation need to test and record flow resistance loss. The blank space “-” represents “no such index”.

[0038] Furthermore, combining Tables 1 and 2, it can be seen that the temperature rise of the experimental group at 2500A is 76.1% lower than that of the control group 1, and it still meets the ≤60K limit at 3500A (the traditional scheme has exceeded the limit). This proves that the heat dissipation design of the U-shaped flow channel group 201 has a significant breakthrough. Therefore, the design of the flow channel group adopting a U-shaped structure and covering the heat generation area in the scheme is reasonable and feasible.

[0039] Furthermore, the busbar liquid-cooled connector of this solution also includes symmetrically arranged plug rods 300 and protective side plates 400. The protective side plates 400 are symmetrically arranged, and the connectors 100 are symmetrically arranged between the protective side plates 400. A second gap X2 is formed between the two connectors 100. The grounding busbar of the busbar is fixedly plugged into the second gap X2. The gap size matches the grounding busbar to ensure reliable grounding. A third gap X3 is formed between the connectors 100 and the protective side plates 400. The protective plate of the busbar is fixedly plugged into the third gap X3. The plugging and matching of the protective plate of the busbar with the third gap X3 has both protective and auxiliary fixing functions.

[0040] The third gap X3 consists of a guide section X31 and a positioning sealing section X32 from the outside in. The inner diameter of the guide section X31 is larger than the inner diameter of the positioning sealing section X32, forming a stepped surface. The inner sidewall of the positioning sealing section X32 has at least one annular sealing groove, and an insulating sealing ring X321 is embedded in the annular sealing groove. The protective plate is inserted into the positioning sealing section X32 through the guide section X31 and is interference-fitted with the insulating sealing ring X321.

[0041] The side wall of the positioning sealing section X32 is also provided with a pressure relief hole 322 that communicates with the outer side of the protective side plate 400. The pressure relief hole 322 of the positioning sealing section X32 can balance the air pressure changes in the gap, such as gas expansion caused by temperature rise, to prevent the protective plate from being deformed by pressure and improve the structural stability.

[0042] The insert rod 300 is inserted into one protective side plate 400, passes through the connector 100 and the cooling component 200, and exits into the other protective side plate 400.

[0043] An insulating sleeve 301 is fixedly sleeved on the outside of the insert rod 300. The insulating sleeve 301 is made of high voltage and high temperature resistant material to prevent leakage. An insulating block 302 is also fixedly sleeved on the outside of the insert rod 300 at both ends of the insulating sleeve 301. The insulating block 302 is axially positioned to prevent the components from shifting. The connector 100 and the cooling component 200 are sleeved on the outside of the insulating sleeve 301, and the protective side plate 400 is sleeved on the outside of the insulating block 302.

[0044] In particular, at least a portion of the fixed groove 401 is connected to the pressure relief hole 322, and the gasket 402 avoids the opening position of the pressure relief hole 322, which can further improve the heat dissipation efficiency.

[0045] The outer wall of the protective side plate 400 is provided with a fixing groove 401. Washers 402 are symmetrically arranged in the fixing groove 401. The washers 402 are made of elastic metal material to buffer vibration. The fixing groove 401 can limit the washers 402 to prevent slippage. The washers 402 are fixedly sleeved on the outside of the insert rod 300.

[0046] One end of the insertion rod 300 is fixed with an abutment block 303, and the outer wall of the washer 402 on this side abuts against the abutment block 303. The other end of the insertion rod 300 is threaded with a square nut 304, which can prevent rotation. The outer wall of the washer 402 on this side abuts against the square nut 304. The components are tightly fitted by bidirectional compression.

[0047] The cooling component 200 includes a cooling plate 202 and a first guide pipe 203 and a second guide pipe 204 fixed at both ends thereon. The three are welded and sealed to prevent refrigerant leakage. The first guide pipe 203 and the second guide pipe 204 are fixed to the first end 202a and the second end 202b of the cooling plate 202 respectively.

[0048] The flow channel assembly 201 includes a first flow channel A1 and a second flow channel A2 symmetrically arranged, with a first end 202a and a second end 202b corresponding to the ends of the first flow channel A1 and the second flow channel A2, respectively. A first cooling zone 202c and a second cooling zone 202d are symmetrically arranged on the cooling plate 202, with the first cooling zone 202c and the second cooling zone 202d respectively corresponding to the busbar insertion positions on both sides. Both ends of the first cooling zone 202c and the second cooling zone 202d intersect with the first end 202a and the second end 202b.

[0049] The first flow channel A1 and the second flow channel A2 are respectively located in the first cooling zone 202c and the second cooling zone 202d. A third flow channel A3 is opened in the second guide pipe 204, and the third flow channel A3 connects the first flow channel A1 and the second flow channel A2.

[0050] Furthermore, the number of first flow channels A1 and second flow channels A2 is equal, and the scheme provides two implementation schemes: one is a single set of flow channels that completely covers the cooling area, and the other is multiple sets of parallel flow channels that are evenly distributed in the cooling area.

[0051] Furthermore, to clarify the applicable scenarios for the two schemes, a comparative experiment on the adaptability of the number of flow channels was conducted: Specifically, this set of tests is to verify the advantages of adapting single / multiple flow channels according to current in terms of temperature rise, cost, and energy consumption compared to the fixed number of channels, and to solve the problem of "insufficient high current and high cost for low current".

[0052] The comparison objects and test conditions are shown in Table 3 below: Table 3 Control group 1 Fixed single flow channel (one channel is used regardless of current). Control group 2 Four fixed flow channels (four channels are used regardless of the current). Experimental group 1 This solution uses a single flow channel (compatible with 1000-2500A). Experimental group 2 This solution has 3 flow channels (compatible with 2500-3500A). Experimental group 3 This solution has 6 flow channels (compatible with 3500-5500A).

[0053] The test conditions were: current gradients of 1000A, 2000A, 3000A, 4500A, and 5500A; the environmental / refrigerant parameters were the same as those in the first group of tests mentioned above. The relative cost was calculated with a single flow channel cost of 1.0.

[0054] Further, the specific steps are as follows: the five groups of samples are identical except for the number of flow channels; they are tested under different working conditions, the temperature rise and flow resistance are recorded, the processing time and material usage are calculated, the relative cost is calculated, and it is evaluated whether the "temperature rise ≤ 60K+ cost is optimal" condition is met.

[0055] The specific results are shown in Table 4 below: Table 4 Control group 1 3000 72.3 980 1.0 no Temperature rise exceeds standard Control group 2 1000 8.2 1850 1.8 yes Too high cost Experimental group 1 2000 18.2 920 1.0 yes Optimal Experimental group 2 3000 30.1 1580 1.5 yes Optimal Experimental group 3 5500 47.3 2680 2.2 yes Optimal

[0056] Table 4 above clearly states that 2500A is the critical dividing line, that is, ≤2500A uses a single flow channel, cost 1.0, temperature rise ≤18.2K, 2500~3500A uses 3 flow channels, cost 1.5, temperature rise ≤36.8K, and above 3500A uses 6 flow channels. Therefore, the "single / multiple channels selectable" design in the solution is creative and can be adapted to different current scenarios.

[0057] Furthermore, the first guide pipe 203 has an independent inlet channel 203a and an outlet channel 203b, allowing for independent refrigerant entry and exit to avoid mixing. The inlet channel 203a connects to the first flow channel A1, and the outlet channel 203b connects to the second flow channel A2. The first guide pipe 203 also has symmetrically fixed inlet pipes 203c and 203d for easy connection to an external refrigerant system. The inlet pipes 203c and 203d connect to the inlet channel 203a and the outlet channel 203b, respectively.

[0058] Furthermore, a heat dissipation zone 202e is formed between the first cooling zone 202c and the second cooling zone 202d. The heat dissipation zone 202e is the exposed surface of the cooling plate, which assists in natural convection. The insert rods 300 are symmetrically arranged in the heat dissipation zone 202e, without obstructing the heat dissipation path, and making reasonable use of space.

[0059] Specifically, the connector 100 includes symmetrically arranged busbar clamps 101, with a fourth gap X4 formed between the busbar clamps 101. The size of the gap X4 is adapted to the thickness of the cooling component 200, and the cooling component 200 is fixed within the fourth gap X4. The busbar clamps 101 include symmetrically arranged first clamps 101a and second clamps 101b, with the first gap X1 located between the first clamps 101a and second clamps 101b. Conductor bars 101a-1 are fixedly embedded on the inner walls of the first clamps 101a and second clamps 101b within the first gap X1. The conductor bars 101a-1 are preferably made of high-conductivity copper, which can improve electrical connection and heat conduction efficiency. A single set of conductors of the conductor busbar P in the busbar groove can be inserted into the first gap X1.

[0060] Furthermore, a baffle 101a-2 is provided in the fourth gap X4. The baffle 101a-2 is provided on both sides of the cooling component 200 and fixed to the side wall of the first clamping plate 101a. The baffle 101a-2 can laterally limit the cooling component and enhance the rigidity of the clamping plate.

[0061] To further optimize the heat dissipation efficiency of the flow channel and determine the optimal cross-sectional shape, this embodiment conducts comparative experiments on the optimization of flow channel cross-sectional shapes for five common flow channel cross-sections, as detailed below: The comparison objects and test conditions are shown in Table 5 below: Table 5 Control group 1 Rectangle: 10mm × 6mm (60mm²) Control group 2 Equilateral triangle: side length 10mm (43.3mm²) Control group 3 Trapezoid: Top base 8mm × Bottom base 12mm × Height 6mm (60mm²) Experimental group 1 Circular: Φ8mm (50.27mm²) Experimental group 2 Elliptical groove: major axis 12mm × minor axis 6mm + groove depth 2mm (56.52mm²)

[0062] The test conditions were: rated current 2500A; refrigerant flow rate 1.1m / s; batch processing of 50 pieces; statistical dimensional accuracy compliance rate; tolerance ±0.1mm.

[0063] Further, the specific steps are as follows: CNC milling of flow channels with different cross sections, ensuring that the cooling plate has the same dimensions, connecting to the refrigerant system, recording the heat transfer coefficient (temperature rise back calculation) and pressure loss, inspecting the dimensions of 50 samples, calculating the pass rate, and scoring comprehensively based on "heat transfer (40%) + flow resistance (30%) + processing (30%)".

[0064] The specific results are shown in Table 6 below: Table 6 Control group 1 2100 980 85 92 High heat exchange scenarios Control group 2 1680 1120 75 75 No recommendations Control group 3 1950 1050 80 85 Special space scene Experimental group 1 1850 850 95 88 Long-distance refrigerant piping (low flow resistance) Experimental group 2 2020 900 92 93 General Scenario (Optimal)

[0065] Combining Tables 5 and 6, the straight-groove elliptical cross-section is the best overall, while the circular cross-section is suitable for low flow resistance scenarios. Therefore, the flow channel cross-section in the scheme should preferably be either straight-groove elliptical or circular, taking into account heat exchange, flow resistance, and processing feasibility, proving that the cross-section selection is non-obvious.

[0066] To better utilize the aforementioned busbar liquid-cooled connector, this embodiment also proposes a busbar liquid-cooled connector assembly method, applicable to the aforementioned busbar liquid-cooled connector, comprising the following steps: First, the core components are pre-assembled. The two ends of the connector 100 are fixed and sealed by welding to ensure that there is no refrigerant leakage. After the inlet and outlet pipes are installed, the flow channel is verified by pressure test.

[0067] The inner wall of the clamp of the connector 100 is fitted with a conductive busbar 101a-1 and is firmly attached by adhesive and bolt to ensure electrical and thermal conductivity. The baffles 101a-2 are symmetrically fixed on the side wall of the clamp. The insert rod 300 is fitted with an insulating sleeve 301 and insulating blocks 302 at both ends in sequence, and a stop block 303 is welded to one end.

[0068] Then, the cooling component 200 is embedded into the fourth gap X4 of the connector 100 and precisely positioned by the baffle 101a-2 to ensure that the cooling area corresponds completely with the conductor busbar P plug position; the plug rod 300 is inserted from one side of the protective side plate 400, passes through the heat dissipation area 202e of the connector 100 and the cooling component 200 in sequence, and comes out from the other side. The washer 402 is installed in the fixing groove 401 on the outer wall of the protective side plate 400, and the square nut 304 at the end is tightened to the preset torque to ensure that all components fit tightly.

[0069] Then, the conductor busbar P is inserted into the first gap X1 of the connector 100, and a feeler gauge is used to ensure that it fits tightly with the conductive busbar 101a-1; the grounding busbar is inserted into the second gap X2 between the two connectors 100 and fixed with a snap fastener.

[0070] The protective plate is inserted into the third gap X3 between the connector 100 and the protective side plate 400. After all components are in place, a continuity test and a sealing test are performed to complete the overall assembly.

[0071] Finally, it should be noted that the methods and devices described in detail above are merely embodiments, and those skilled in the art can modify these embodiments in different ways as long as they do not depart from the scope of the present invention.

Claims

1. A busbar trunking liquid-cooled connector, characterized in that: include, A symmetrically arranged connector (100) is provided, and a cooling element (200) is provided inside the connector (100). The cooling element (200) separates the connector (100) to form a symmetrically arranged first gap (X1). The cooling component (200) has at least one set of flow channels (201) inside, the flow channels (201) cover the heating area of ​​the conductor busbar (P) fixed in the first gap (X1) on both sides, and the inlet and outlet of the flow channels (201) are located on the same side. It also includes symmetrically arranged insert rods (300) and protective side plates (400). The protective side plates (400) are symmetrically arranged, and the connectors (100) are symmetrically arranged between the protective side plates (400). A second gap (X2) is formed between the connectors (100) on both sides. The grounding busbar of the busbar is fixedly inserted into the second gap (X2). A third gap (X3) is formed between the connectors (100) and the protective side plates (400). The protective plate of the busbar is fixedly inserted into the third gap (X3). The third gap (X3) includes a guide section (X31) and a positioning sealing section (X32) from the outside to the inside. The inner diameter of the guide section (X31) is larger than the inner diameter of the positioning sealing section (X32), forming a stepped surface. The inner sidewall of the positioning sealing section (X32) has at least one annular sealing groove. An insulating sealing ring (X321) is embedded in the annular sealing groove. The protective plate is inserted into the positioning sealing section (X32) through the guide section (X31) and is interference-fitted with the insulating sealing ring (X321). The side wall of the positioning sealing section (X32) is also provided with a pressure relief hole (322) that communicates with the outside of the protective side plate (400). The insert (300) is inserted into one protective side plate (400), passes through the connector (100) and the cooling component (200), and exits into the other protective side plate (400); An insulating sleeve (301) is fixedly sleeved on the outside of the insert (300), and insulating blocks (302) are also fixedly sleeved on the outside of the insert (300) at both ends of the insulating sleeve (301). The connector (100) and the cooling component (200) are sleeved on the outside of the insulating sleeve (301), and the protective side plate (400) is sleeved on the outside of the insulating blocks (302). The outer wall of the protective side plate (400) is provided with a fixing groove (401), and washers (402) are symmetrically arranged in the fixing groove (401). The washers (402) are fixedly sleeved on the outside of the insert rod (300). In this case, at least a portion of the fixed groove (401) is connected to the pressure relief hole (322), and the gasket (402) avoids the opening position of the pressure relief hole (322); One end of the insert rod (300) is fixed with an abutment block (303), and the outer wall of the washer (402) on this side abuts against the abutment block (303). The other end of the insert rod (300) is threaded with a square nut (304), and the outer wall of the washer (402) on this side abuts against the square nut (304).

2. The busbar liquid-cooled connector according to claim 1, characterized in that: The cooling component (200) includes a cooling plate (202) and a first guide pipe (203) and a second guide pipe (204) fixed at both ends thereon. The first guide pipe (203) and the second guide pipe (204) are fixed to the first end (202a) and the second end (202b) of the cooling plate (202) respectively. The flow channel group (201) includes a first flow channel (A1) and a second flow channel (A2) arranged symmetrically, with the first end (202a) and the second end (202b) corresponding to the two ends of the first flow channel (A1) and the second flow channel (A2); The cooling plate (202) is symmetrically provided with a first cooling zone (202c) and a second cooling zone (202d), and both ends of the first cooling zone (202c) and the second cooling zone (202d) intersect with the first end (202a) and the second end (202b); The first flow channel (A1) and the second flow channel (A2) are respectively located in the first cooling zone (202c) and the second cooling zone (202d). A third flow channel (A3) is opened in the second guide pipe (204), and the third flow channel (A3) connects the first flow channel (A1) and the second flow channel (A2).

3. The busbar liquid-cooled connector according to claim 2, characterized in that: The number of the first flow channel (A1) and the second flow channel (A2) is equal; The first flow channel (A1) and the second flow channel (A2) are provided in only one set, and the first flow channel (A1) and the second flow channel (A2) completely cover the first cooling zone (202c) and the second cooling zone (202d), respectively. Alternatively, the first flow channel (A1) and the second flow channel (A2) are provided in parallel in several groups, and the first flow channel (A1) and the second flow channel (A2) are evenly distributed in the first cooling zone (202c) and the second cooling zone (202d).

4. The busbar liquid-cooled connector according to claim 3, characterized in that: The first guide pipe (203) has an independent inlet channel (203a) and an outlet channel (203b). The inlet channel (203a) is connected to the first flow channel (A1), and the outlet channel (203b) is connected to the second flow channel (A2). The first guide pipe (203) is also symmetrically fixed with an inlet pipe (203c) and an outlet pipe (203d), which are connected to the inlet channel (203a) and the outlet channel (203b) respectively.

5. The busbar liquid-cooled connector according to claim 3 or 4, characterized in that: A heat dissipation zone (202e) is formed between the first cooling zone (202c) and the second cooling zone (202d), and the insert (300) is symmetrically arranged in the heat dissipation zone (202e).

6. The busbar liquid-cooled connector according to any one of claims 1 to 4, characterized in that: The connector (100) includes symmetrically arranged busbar clamps (101), a fourth gap (X4) is formed between the busbar clamps (101), and the cooling component (200) is fixed in the fourth gap (X4); The busbar clamp (101) includes a first clamp (101a) and a second clamp (101b) arranged symmetrically. The first gap (X1) is located between the first clamp (101a) and the second clamp (101b). Conductor bars (101a-1) are fixedly embedded on the inner walls of the first clamp (101a) and the second clamp (101b) within the first gap (X1). A single set of conductors of the conductor busbar (P) in the busbar groove can be inserted into the first gap (X1).

7. The busbar liquid-cooled connector according to claim 6, characterized in that: A baffle (101a-2) is provided in the fourth gap (X4). The baffle (101a-2) is blocked on both sides of the cooling component (200) and fixed to the side wall of the first clamping plate (101a).

8. A method for assembling a busbar trunking liquid-cooled connector, characterized in that: The busbar liquid-cooled connector as described in any one of claims 1 to 7 includes the following steps: First, the core components are pre-assembled. The guide pipes at both ends of the connector (100) are fixed and sealed. After the inlet and outlet pipes are installed, the flow channel is ensured to be connected. The inner wall of the clamp of the connector (100) is fitted with conductive busbars (101a-1) and they are firmly attached. The baffles (101a-2) are symmetrically fixed on the side wall of the clamp. The insulating sleeve (301) and the insulating blocks (302) at both ends are sequentially fitted on the outside of the insert (300). The abutment block (303) is fixed at one end. Then, the cooling component (200) is embedded into the gap of the connector (100) and precisely positioned by the baffle (101a-2) to ensure that the cooling area corresponds to the conductor busbar (P) insertion position; the plug rod (300) is inserted from one side of the protective side plate (400), passes through the heat dissipation area of ​​the connector (100) and the cooling component (200) in sequence, and comes out from the other side. A washer (402) is installed in the fixing groove (401) on the outer wall of the protective side plate (400), and the end is tightened with a square nut (304); Then the conductor busbar (P) is inserted into the gap of the connector (100) to ensure a tight fit with the conductive busbar (101a-1); the grounding busbar is inserted into the gap between the two connectors (100), and the protective plate is inserted into the gap between the connector (100) and the protective side plate (400). All components are inserted into place to complete the overall assembly.

Images