Capacitor double-layer copper bar creepage distance fixing process for new energy automobile

Abstract

The invention discloses a capacitor double-layer copper bar creepage distance fixing technology for a new energy automobile. The technology comprises the following steps that S1, a plurality of positioning installation holes are formed in a first copper bar; s2, an isolation supporting cushion piece is placed in a positioning installation hole of the first copper bar, then the second copper bar is placed on the isolation supporting cushion piece, and the first copper bar, the second copper bar and the isolation supporting cushion piece jointly form a copper bar assembly; and S3, the copper bar assembly is placed in an injection mold, a main body plastic part is formed through injection molding of the injection mold, a main body of the copper bar assembly is wrapped in the main body plastic part, and the connecting copper pins of the copper bar assembly are exposed out of the main body plastic part. According to the invention, the first copper bar and the second copper bar are separated by adopting the isolation supporting pad, so that the situation that the distance between the first copper bar and the second copper bar is too small due to bending of the copper bars during injection molding can be prevented, sufficient creepage distance between the first copper bar and the second copper bar is ensured, and potential safety hazards such as short circuit and electric leakage are avoided.

Description

Technical Field

[0001] This invention relates to the technical field of electrical technology for new energy vehicles, and in particular to a process for fixing the creepage distance of double-layer copper busbars for capacitors in new energy vehicles. Background Technology

[0002] In the design and manufacturing of high-voltage capacitor components for new energy vehicles, double-layer copper busbars, as the core conductive carrier, must simultaneously meet the dual requirements of high-voltage insulation safety and structural stability. New energy vehicle capacitor components operate at high voltages, imposing stringent standards on creepage distance and insulation performance: the T+ and T- terminals must withstand 3000Vac high voltage for 30 seconds, with a leakage current not exceeding 0.6mA. While traditional double-layer high-temperature resistant insulating paper insulation solutions can achieve basic insulation, they cannot solve the structural deformation problem during injection molding. Once the copper busbars shift or deform, it directly leads to insufficient creepage distance, causing short circuits, leakage, and other safety hazards, threatening the stability of the vehicle's high-voltage electrical system. Furthermore, traditional processes use a 1.5mm gap between the upper and lower copper busbars, embedded in the mold for integrated molding. During injection molding, the impact force of the high-voltage melt easily causes the thin copper busbars to bend, shift position, and damage the surface integrity, resulting in reduced conductivity and even altering the preset spacing between the copper busbars, directly exceeding the insulation safety threshold between the double-layer copper busbars. Therefore, we propose a process for fixing the creepage distance of double-layer copper busbars for new energy vehicles. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a process for fixing the creepage distance of double-layer copper busbars for capacitors in new energy vehicles.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles, comprising the following steps: S1. Several positioning and mounting holes are opened at the first copper busbar. S2. Place the isolation support pad in the positioning mounting hole of the first copper busbar, and then place the second copper busbar on the isolation support pad. The upper side of the isolation support pad abuts against the second copper busbar, and the lower side of the isolation support pad abuts against the first copper busbar. The first copper busbar, the second copper busbar, and the isolation support pad together constitute a copper busbar assembly. S3. Place the copper busbar assembly into the injection mold, and the injection mold injection molds out the main plastic part. The main body of the copper busbar assembly is covered inside the main plastic part, and the connecting copper feet of the copper busbar assembly are exposed outside the main plastic part.

[0005] To elaborate further, the isolation support pad is provided with a plug-in post, and a support part is provided on the upper side of the plug-in post, and the support part is in the shape of a frustum.

[0006] To further elaborate, the edge of the vertical section of the isolation support pad includes a first creepage distance, a second creepage distance, and a third creepage distance, and the sum of the first creepage distance, the second creepage distance, and the third creepage distance is greater than 5mm.

[0007] To elaborate further, the material of the isolation support pad is PPS.

[0008] To elaborate further, the distance between the first copper busbar and the second copper busbar is 1.5 mm.

[0009] To further elaborate, the surface of the first copper busbar that contacts the isolation support pad is the first support surface, and the surface of the second copper busbar that contacts the isolation support pad is the second support surface. The flatness of the first support surface and the second support surface is less than 0.1.

[0010] To elaborate further, when the first copper busbar and the second copper busbar are subjected to a high voltage of 3000Vac for 30 seconds, the leakage current does not exceed 0.6mA.

[0011] The beneficial effects of the present invention are as follows: The present invention uses an isolation support pad to separate the first copper busbar and the second copper busbar, which can prevent the copper busbar from bending during injection molding and causing the distance between the two to be too small, ensuring that there is sufficient creepage distance between the first copper busbar and the second copper busbar, and avoiding safety hazards such as short circuit and leakage. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the finished product of the present invention.

[0013] Figure 2 for Figure 1 Structural cross-sectional view of the finished product.

[0014] Figure 3 for Figure 2 A magnified view of a portion of point A.

[0015] Figure 4 A schematic diagram of the structure in which the isolation support pad is placed on the first copper busbar.

[0016] Figure 5 This is a schematic diagram of the structure where the second copper busbar is placed on the isolation support pad.

[0017] Reference numerals: 10, First copper busbar; 11, First support surface; 12, Positioning mounting hole; 20, Second copper busbar; 21, Second support surface; 30, Isolation support pad; 301, First creepage distance; 302, Second creepage distance; 303, Third creepage distance; 31, Insertion post; 32, Support part; 40, Main plastic part. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings.

[0019] Combined with appendix Figure 4 and attached Figure 5 As shown, a process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles includes the following steps: S1. Several positioning and mounting holes 12 are opened at the first copper busbar 10; S2, as attached Figure 4 As shown, the isolation support pad 30 is placed in the positioning mounting hole 12 of the first copper busbar 10. The material of the isolation support pad 30 is PPS, as shown in the attached diagram. Figure 5 As shown, the second copper busbar 20 is then placed on the isolation support pad 30. The upper side of the isolation support pad 30 abuts against the second copper busbar 20, and the lower side of the isolation support pad 30 abuts against the first copper busbar 10. The first copper busbar 10, the second copper busbar 20 and the isolation support pad 30 together constitute the copper busbar assembly. S3. Place the copper busbar assembly into the injection mold. The injection mold will then mold the main plastic part 40. The main body of the copper busbar assembly is encased within the main plastic part 40, while the connecting copper feet of the copper busbar assembly are exposed outside the main plastic part 40. The finished product is shown in the attached figure. Figure 1 As shown.

[0020] Combined with appendix Figure 2 and attached Figure 3 As shown, the isolation support pad 30 has a plug-in post 31, and a support part 32 is provided on the upper side of the plug-in post 31. The support part 32 is frustum-shaped. (See attached image) Figure 3 As shown, the edge of the vertical section of the isolation support pad 30 includes a first creepage distance 301, a second creepage distance 302, and a third creepage distance 303, and the sum of the first creepage distance 301, the second creepage distance 302, and the third creepage distance 303 is greater than 5mm.

[0021] As attached Figure 5 As shown, the distance between the first copper busbar 10 and the second copper busbar 20 is H, where H = 1.5 mm. The surface of the first copper busbar 10 that contacts the isolation support pad 30 is the first support surface 11, and the surface of the second copper busbar 20 that contacts the isolation support pad 30 is the second support surface 21. The flatness of the first support surface 11 and the second support surface 21 is less than 0.1. When the first copper busbar 10 and the second copper busbar 20 are subjected to a 3000Vac high voltage for 30 seconds, the leakage current does not exceed 0.6mA.

[0022] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] It should be understood that the terms "first," "second," etc., are used in this invention to describe various types of information, but these terms are not limited to them; they are only used to distinguish information of the same type from one another. For example, without departing from the scope of this invention, "first" information may also be referred to as "second" information, and similarly, "second" information may also be referred to as "first" information.

[0024] The above does not limit the technical scope of the present invention in any way. Any modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the technical scope of the present invention.

Claims

1. A process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles, characterized in that: It includes the following steps: S1. Several positioning and mounting holes (12) are opened at the first copper busbar (10). S2. Place the isolation support pad (30) in the positioning mounting hole (12) of the first copper busbar (10), and then place the second copper busbar (20) on the isolation support pad (30). The upper side of the isolation support pad (30) abuts against the second copper busbar (20), and the lower side of the isolation support pad (30) abuts against the first copper busbar (10). The first copper busbar (10), the second copper busbar (20), and the isolation support pad (30) together constitute a copper busbar assembly. S3. The copper busbar assembly is placed into the injection mold, and the injection mold is used to inject the main plastic part (40). The main body of the copper busbar assembly is covered inside the main plastic part (40), and the connecting copper feet of the copper busbar assembly are exposed outside the main plastic part (40).

2. The process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 1, characterized in that: The isolation support pad (30) is provided with a plug-in post (31), and a support part (32) is provided on the upper side of the plug-in post (31). The support part (32) is in the shape of a frustum.

3. The process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 2, characterized in that: The edge of the vertical section of the isolation support pad (30) includes a first creepage distance (301), a second creepage distance (302), and a third creepage distance (303), and the sum of the first creepage distance (301), the second creepage distance (302), and the third creepage distance (303) is greater than 5 mm.

4. A process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 1 or 2, characterized in that: The material of the isolation support pad (30) is PPS.

5. The process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 1, characterized in that: The distance between the first copper busbar (10) and the second copper busbar (20) is 1.5 mm.

6. The process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 1, characterized in that: The surface of the first copper busbar (10) that contacts the isolation support pad (30) is the first support surface (11), and the surface of the second copper busbar (20) that contacts the isolation support pad (30) is the second support surface (21). The flatness of the first support surface (11) and the second support surface (21) is less than 0.

1.

7. The process for fixing the creepage distance of a double-layer copper busbar for capacitors in new energy vehicles according to claim 1, characterized in that: The leakage current of the first copper busbar (10) and the second copper busbar (20) does not exceed 0.6mA when subjected to a high voltage of 3000Vac for 30 seconds.

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