Bus duct connector sealing structure and sealing process thereof

Abstract

The invention relates to the technical field of bus ducts, and discloses a bus duct connector sealing structure and a sealing technology thereof.The sealing technology comprises the following steps that a plurality of conducting bars are provided, and the surfaces of the conducting bars are cleaned; shielding an electrical connection part reserved on the conducting bar; the conducting bar is preheated and then immersed in epoxy resin insulation powder, the powder is attached to the surface, except for the electrical connection part, of the conducting bar, then curing treatment is carried out to form an epoxy resin insulation layer, and shielding is removed; the two groups of conducting bars are arranged in the assembling cavity of the bus duct connector, and electric connection is completed through the connecting assembly; a plurality of sealing plates are detachably installed on the bus duct connector so as to temporarily seal the assembly cavity, and liquid sealant is injected into the assembly cavity through the sealant injection hole; and after the liquid sealant is solidified in the assembling cavity to form a sealant body, the sealing plate is detached. According to the sealing process and the sealing structure provided by the invention, the sealing performance of the bus duct connector is effectively improved.

Description

Technical Field

[0001] This application relates to the technical field of busbar trunking, and in particular to a sealing structure for a busbar trunking connector and its sealing process. Background Technology

[0002] In electrical systems, busbar trunking, as a highly efficient power transmission device, is widely used in industrial plants, commercial buildings and other places. In some humid working environments, busbar trunking connectors are often corroded by environmental factors such as moisture and dust. This corrosion not only reduces the electrical performance of the busbar trunking connectors, such as increasing contact resistance and reducing insulation performance, but may also cause safety accidents such as short circuits, seriously affecting the stable operation of the electrical system.

[0003] Existing technologies generally employ an "external encapsulation" method, primarily relying on installing sealing gaskets or adding external sealing covers at the joint of the connector housing. This approach has fundamental drawbacks: First, sealing gaskets are prone to creep under long-term pressure, leading to a gradual decline in sealing performance over time. This is especially true under cyclical temperature conditions, where material aging accelerates, significantly increasing the risk of seal failure. Second, while external sealing covers provide a physical barrier, limitations in installation precision mean that even small gaps at the joint surface can become channels for moisture penetration. Furthermore, the difference in thermal expansion coefficients between the cover and the connector can easily create gaps under extreme temperature conditions, failing to form a durable and reliable sealing barrier.

[0004] Therefore, developing a sealing structure for busbar trunking connectors to effectively improve their sealing performance has become a key issue that urgently needs to be addressed in the field of electrical system safety. Summary of the Invention

[0005] To address the technical problem of poor sealing in existing busbar trunking connectors, this application provides a sealing structure and sealing process for a busbar trunking connector.

[0006] A sealing process for a busbar trunking connector includes the following steps: Step S1: Provide multiple conductive busbars and perform surface cleaning treatment on the conductive busbars; Step S2: Shield and protect the electrical connection portion reserved on the conductive busbar; Step S3: Preheat the conductive bus from step S2, then immerse it in epoxy resin insulating powder, so that the epoxy resin insulating powder adheres to the surface of the conductive bus except for the electrical connection part, then perform curing treatment to form an epoxy resin insulating layer on the surface, and remove the shielding of the electrical connection part. Step S4: Place the two sets of conductive busbars processed in step S3 into the assembly cavity of the busbar connector, and make the electrical connection parts of the two sets of conductive busbars electrically connected through the connection assembly; Step S5: Multiple sealing plates are detachably installed on the busbar connector to temporarily seal the assembly cavity. The sealing plate at the top of the busbar connector is provided with an injection hole, through which liquid sealant is injected into the assembly cavity. Step S6: After the liquid sealant has cured and formed a sealing colloid in the assembly cavity, remove the sealing plate; Specifically, steps S1-S3 are the insulation and waterproofing process for the conductive busbar, and steps S4-S6 are the potting and waterproofing process for the busbar trunking connector.

[0007] By adopting the above technical solution, the surface of the conductive busbar is first cleaned to remove surface impurities, providing a good foundation for subsequent processes. Then, the pre-reserved electrical connection parts on the conductive busbar are shielded and protected to prevent the insulation layer from covering the electrical connection parts and affecting the electrical connection performance. Next, the conductive busbar is preheated and immersed in epoxy resin insulating powder, and then cured to form an epoxy resin insulating layer. This ensures that the surface of the conductive busbar except for the electrical connection parts is reliably insulated, effectively reducing the erosion of the conductive busbar by external moisture, dust, etc., which is one of the key steps to achieve sealing and waterproofing. Then, the two sets of treated conductive busbars are placed into the assembly cavity of the busbar trunking connector and the electrical connection is completed. After that, a sealing plate with an injection hole is used to temporarily seal the assembly cavity and inject liquid sealant. This injection process fills the gaps in the assembly cavity. After the liquid sealant cures to form a sealing colloid, a complete sealing barrier is formed, preventing moisture, dust, etc. from entering, further enhancing the sealing performance of the busbar trunking connector. This sealing process, through the synergistic effect of insulation and waterproofing techniques and potting waterproofing, constructs a complete protection system from the insulation treatment of the busbar to the overall sealing of the connector. This greatly improves the sealing and waterproofing performance of the busbar connector, effectively avoids the degradation of electrical performance and safety accidents such as short circuits caused by environmental factors, and ensures the stable operation of the electrical system.

[0008] Further, in step S3, the curing process includes pre-curing and secondary curing: after the epoxy resin insulating powder is attached to the surface of the conductive busbar except for the electrical connection overlap surface, pre-curing is performed first to form the epoxy resin insulating layer, then the shielding is removed, and secondary curing is performed.

[0009] By adopting the above technical solution, the curing process is divided into pre-curing and secondary curing stages. First, pre-curing allows the epoxy resin insulating powder adhering to the outer surface of the electrical connection lap surface of the busbar to initially form an epoxy resin insulating layer, preventing it from detaching or shifting during subsequent operations and ensuring the integrity and uniformity of the insulating layer. Then, the shielding is removed for secondary curing, making the epoxy resin insulating layer bond more tightly to the surface of the busbar, effectively enhancing the insulation effect of the busbar and laying a solid foundation for the overall sealing of the busbar connection. This staged curing process allows for better control of the epoxy resin insulating layer formation process, ensuring that the busbar reaches an ideal insulation state, thereby guaranteeing the long-term stable operation of the busbar connection under complex working conditions, greatly reducing the risk of electrical faults caused by seal failure, and improving the safety and stability of the electrical system.

[0010] Further, in step S3, the preheating temperature is 180-220℃, the preheating time is 20-30 min, the pre-curing temperature is 200-220℃, the pre-curing time is 20-30 min, the secondary curing temperature is 240℃-260℃, and the re-curing time is 40-50 min.

[0011] By adopting the above technical solution, setting the preheating temperature to 180-220℃ and the preheating time to 20-30 minutes ensures that the conductive busbar is heated evenly, which is beneficial for better adhesion of the epoxy resin insulating powder. The pre-curing temperature is 200-220℃ and the pre-curing time is 20-30 minutes, which ensures that the epoxy resin insulating powder initially forms a stable and uniform insulating layer. The secondary curing temperature is 240℃-260℃ and the re-curing time is 40-50 minutes, which further enhances the performance of the epoxy resin insulating layer, improves its insulation effect and stability, and thus improves the electrical and sealing performance of the busbar connection.

[0012] Further, in step S5, the liquid sealant comprises 100 parts of insulating resin matrix, 150-200 parts of thermally conductive insulating filler, 20-50 parts of curing agent, and 2-10 parts of additives.

[0013] By adopting the above technical solution, the liquid sealant is controlled within a suitable mixing ratio range. On the one hand, the insulating resin matrix provides the basic adhesion, flexibility, and electrical insulation properties of the sealant. On the other hand, the addition of a variety of thermally conductive and insulating fillers effectively improves the thermal conductivity of the sealant. The liquid sealant, with the synergistic effect of multiple components, is injected into the busbar trunking connector and can be cured in the assembly cavity of the busbar trunking connector to form a dense and stable sealant. This effectively isolates corrosive media such as moisture and dust, achieving comprehensive and thorough coverage and protection of the internal electrical connection structure, thereby constructing a durable sealing barrier for the busbar trunking connector.

[0014] Furthermore, the insulating resin matrix is ​​any one of silicone resin, epoxy resin, and polyurethane resin, and the thermally conductive insulating filler includes aluminum nitride powder and flake alumina powder that have been surface-treated with a silane coupling agent, wherein the flake alumina powder accounts for 5% to 20% of the total mass of the thermally conductive insulating filler.

[0015] By adopting the above technical solutions, epoxy resin and polyurethane resin both possess excellent electrical insulation properties, weather resistance, and chemical stability, which can meet the usage requirements of busbar trunking connectors in different environments and provide a reliable insulating foundation for the sealing colloid. The thermally conductive insulating filler uses aluminum nitride powder and flake alumina powder that have been surface-treated with silane coupling agent. The silane coupling agent surface treatment can enhance the interfacial bonding force between the filler and the insulating resin matrix.

[0016] Aluminum nitride powder provides the basic high thermal conductivity, while flake alumina powder acts as a thermal bridge, effectively connecting the aluminum nitride powder particles to synergistically construct a highly efficient thermal network, significantly improving overall heat dissipation capacity. Furthermore, controlling the content of flake alumina between 5% and 20% maximizes thermal conductivity while avoiding problems such as excessive viscosity, uneven dispersion, and increased interface defects caused by excessive addition. This achieves excellent thermal conductivity while maintaining the overall performance of the sealant.

[0017] Furthermore, the epoxy resin insulating powder comprises epoxy resin, epoxy resin curing agent, and electrical insulating filler, wherein the electrical insulating material comprises at least one of silica powder and mica powder.

[0018] By adopting the above technical solution, epoxy resin, as the base component of the epoxy resin insulating powder, provides excellent adhesion and insulation. The epoxy resin curing agent promotes the curing reaction of the epoxy resin, forming a stable insulating layer. The addition of electrical insulating fillers, due to the excellent insulation, heat resistance, and chemical stability of silica powder, effectively improves the voltage resistance and wear resistance of the insulating layer. Mica powder, with its good electrical insulation and high-temperature resistance, enhances the arc resistance and thermal shock resistance of the insulating layer, further strengthening its insulation performance and mechanical strength. Therefore, the epoxy resin insulating powder enables the busbar to form a high-quality epoxy resin insulating layer after treatment, effectively preventing the corrosion of the busbar by moisture and dust, and improving the sealing and electrical performance of the busbar connectors.

[0019] Furthermore, in step S4, the connecting assembly includes at least one composite connecting plate and fasteners. The composite connecting plate is disposed between the electrical connection parts of the two sets of conductive busbars to achieve electrical connection, and the fasteners fix the composite connecting plate to the electrical connection parts of the two sets of conductive busbars.

[0020] By adopting the above technical solution, using composite connecting plates and fasteners to form a connecting assembly to realize the electrical connection and fixation of the electrical connection parts of the two sets of conductive busbars, a stable and reliable electrical connection between the conductive busbars can be ensured, the risk of electrical faults caused by unreliable connections can be reduced, and the electrical performance of the busbar connection head and the stable operation of the electrical system can be guaranteed.

[0021] Furthermore, the composite connecting plate is an integral plate consisting of an upper conductive layer, an intermediate insulating layer, and a lower conductive layer, which are solidified by a hot pressing process. The upper and lower conductive layers are made of copper plates or copper alloy plates, and the intermediate insulating layer is made of epoxy resin plates, mica plates, or polytetrafluoroethylene plates.

[0022] By adopting the above technical solution, the composite connection plate adopts a structure in which an upper conductive layer, a middle insulating layer, and a lower conductive layer are solidified into an integral plate through a hot pressing process. The upper and lower conductive layers are made of copper plates or copper alloy plates with excellent conductivity, which can ensure smooth and stable current transmission. The middle insulating layer is made of epoxy resin board, mica board, or polytetrafluoroethylene board, which has good insulation performance, heat resistance, and chemical stability. It can provide reliable insulation isolation for the upper and lower conductive layers under different working conditions, prevent safety accidents such as leakage and short circuit, and ensure the electrical safety of the bus trunking connector. At the same time, this multi-layer structure design also enhances the overall strength and stability of the composite connection plate, ensuring the long-term stable and reliable operation of the bus trunking connector.

[0023] Furthermore, the busbar connector includes a first housing, a second housing, and a first end plate and a second end plate connecting the first housing and the second housing. The first housing, the first end plate, the second housing, and the second end plate together enclose the assembly cavity. The fastener passes through the first end plate, the composite connecting plate, and the second end plate in sequence, and the fastener is fixed at both ends on the first end plate and the second end plate by a locking member, thereby pressing and fixing the composite connecting plate to the electrical connection part of the two sets of conductive busbars.

[0024] By adopting the above technical solution, the busbar connector adopts a structural design in which a first shell, a second shell, a first end plate, and a second end plate are enclosed to form an assembly cavity. This structure not only provides a stable installation space for the conductive busbars, but also facilitates subsequent sealing treatment. Fasteners pass through the first end plate, the composite connecting plate, and the second end plate in sequence, and are fixed at both ends by locking components. This connection method can ensure that the composite connecting plate is tightly pressed onto the electrical connection part of the two sets of conductive busbars, thereby ensuring the stability and reliability of the electrical connection and further improving the overall strength and durability of the busbar connector.

[0025] Furthermore, in step S6, the sealing colloid completely fills the assembly cavity, and the sealing colloid is seamlessly bonded to the surface of the conductive busbar.

[0026] By adopting the above technical solution, the sealing colloid completely fills the assembly cavity and seamlessly bonds with the surface of the busbar, effectively isolating it from corrosive media such as moisture and dust in all directions and without blind spots. This prevents these media from entering the busbar connector and corroding the busbar, greatly enhancing the sealing and waterproof performance of the busbar connector, thus effectively ensuring the electrical performance of the busbar. Simultaneously, this sealing method has good durability and stability, maintaining a good sealing effect for a longer period, reducing the frequency of later maintenance and replacement, and lowering operating costs.

[0027] Furthermore, this application also provides a sealing structure for a busbar trunking connector, manufactured using the sealing process described above, comprising a busbar trunking connector and two sets of conductive bars. An assembly cavity is formed inside the busbar trunking connector, and the two sets of conductive bars pass through the assembly cavity. The two sets of conductive bars are electrically connected through a connecting assembly. Except for the electrical connection portion, the surface of the conductive bars is covered with an epoxy resin insulating layer, and the assembly cavity is filled with a sealing colloid.

[0028] Furthermore, this application also provides a busbar trunking system, including the busbar trunking connector sealing structure described above.

[0029] In summary, this application includes at least the following beneficial technical effects: (1) By combining the insulation and waterproofing process of the busbar and the potting and waterproofing process of the connector, a double protection is formed, which fundamentally prevents water vapor and dust from entering, greatly improves the sealing and waterproofing performance of the busbar connector, effectively avoids the decline in electrical performance and short circuits caused by environmental factors, and ensures the stable operation of the electrical system.

[0030] (2) By applying the phased curing process, the epoxy resin insulation layer and the busbar are more tightly bonded, which enhances the insulation effect of the busbar and provides a solid foundation for the overall sealing of the busbar connection. This effectively reduces the risk of electrical faults caused by sealing failure and improves the safety and stability of the electrical system.

[0031] (3) The multi-component synergistic effect of the liquid sealant can solidify into a dense and stable sealant in the assembly cavity of the busbar trunking connector, which can comprehensively and without dead angles cover and protect the internal electrical connection structure, build a durable sealing barrier, and effectively isolate water vapor, dust and other corrosive media. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of a busbar trunking structure provided in an embodiment of the present invention; Figure 2 This is an enlarged schematic diagram of structure A of a busbar provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the structure of a busbar connector in the glue injection state according to an embodiment of the present invention; Figure 4 This is an enlarged schematic diagram of structure B of a busbar trunking connector in the glue injection state, according to an embodiment of the present invention.

[0033] Explanation of reference numerals in the attached figures: 1. Busbar trunking body; 2. Busbar trunking connector; 21. Assembly cavity; 22. First housing; 23. Second housing; 24. First end plate; 25. Second end plate; 3. Conductor bar; 31. Epoxy resin insulation layer; 4. Connecting assembly; 41. Composite connecting plate; 42. Fastener; 43. Locking component; 44. Sealing gasket; 5. Sealing plate; 51. Glue injection hole. Detailed Implementation

[0034] The following combination Figure 1-4 The technical solutions in the embodiments of the present invention will be described in detail.

[0035] Example 1 See Figure 1-2 Embodiment 1 of the present invention provides a busbar trunking, comprising a busbar trunking body 1 and a busbar trunking connector sealing structure. The busbar trunking body 1 is equipped with a through conductive busbar 3. The busbar trunking connector sealing structure includes a busbar trunking connector 2 and two sets of conductive busbars 3. The two sets of conductive busbars are formed by two adjacent sections of the busbar trunking body 1 extending into the busbar trunking connector 2 and docking. An assembly cavity 21 is formed in the busbar trunking connector 2. The two sets of conductive busbars 3 pass through the assembly cavity 21 and are electrically connected by a connecting component 4. The surface of the conductive busbars 3, except for the electrical connection part, is covered with an epoxy resin insulating layer 31. The assembly cavity 21 is filled with a sealing colloid, which fills the assembly cavity 21 and is seamlessly bonded to the surface of the conductive busbars 3.

[0036] In this embodiment, the sealant comprises 100 parts of insulating resin matrix, 150-200 parts of thermally conductive insulating filler, 20-50 parts of curing agent, and 2-10 parts of additives.

[0037] The insulating resin matrix is ​​bisphenol A type epoxy resin; the thermally conductive insulating filler is composed of aluminum nitride powder and flake alumina powder treated with silane coupling agent, and the flake alumina powder accounts for 5% to 20% of the total mass of the thermally conductive insulating filler; the curing agent is a modified alicyclic amine curing agent; the additives include fumed silica and benzyl glycidyl ether, and preferably, the silane coupling agent is γ-aminopropyltriethoxysilane (KH-550).

[0038] Specifically, the busbar connector 2 includes a first housing 22, a second housing 23, and a first end plate 24 and a second end plate 25 connecting the first housing 22 and the second housing 23. The first housing 22, the first end plate 24, the second housing 23 and the second end plate 25 together enclose an assembly cavity 21.

[0039] Furthermore, the connecting assembly 4 includes multiple composite connecting plates 41 and fasteners 42. The composite connecting plates 41 are disposed between the electrical connection parts of the two sets of conductive busbars 3 to achieve electrical connection. The fasteners 42 pass through the first end plate 24, the composite connecting plates 41 and the second end plate 25 in sequence. The two ends of the fasteners 42 are fixed to the first end plate 24 and the second end plate 25 respectively by locking members 43. By tightening the locking members 43, the composite connecting plates 41 are firmly pressed and fixed between the electrical connection parts of the two sets of conductive busbars 3, thereby forming a stable electrical connection.

[0040] Specifically, the composite connecting plate 41 is a multi-layer press-fit structure, consisting of an upper conductive layer, a middle insulating layer, and a lower conductive layer, which are bonded together as a single plate through a hot-pressing process. The upper and lower conductive layers are made of copper plates or copper alloy plates; the middle insulating layer is made of epoxy resin board, mica board, or polytetrafluoroethylene board. In this embodiment, the upper and lower conductive layers are made of copper alloy plates, and the middle insulating layer is made of epoxy resin board.

[0041] As an optional implementation, in this embodiment, the fastener 42 is a screw and the locking member 43 is a nut. The screw passes through the first end plate 24, the composite connecting plate 41 and the second end plate 25 in sequence. Both ends are fixed by the screw threaded connection between the nut and the screw. The screw is provided with sealing gaskets 44 at both ends. The sealing gaskets 44 are located between the nut and the first end plate 24 and between the nut and the second end plate 25.

[0042] Example 2 See Figure 1-4 Embodiment 2 of the present invention provides a sealing process for a busbar trunking connector, used in the busbar trunking of Embodiment 1, comprising the following steps: Step S1: Provide multiple conductive busbars 3, perform surface cleaning treatment on the conductive busbars 3 to remove burrs and oil stains from the surface of the conductive busbars 3; Step S2: Shield and protect the electrical connection parts reserved on the conductive busbar 3; Step S3: Preheat the conductive busbar 3 from step S2, then immerse it in epoxy resin insulating powder, so that the epoxy resin insulating powder adheres to the surface of the conductive busbar 3 except for the electrical connection part, and then perform curing treatment to form an epoxy resin insulating layer 31 on the surface, and remove the shielding of the electrical connection part. Step S4: Place the two sets of conductive busbars processed in step S3 into the assembly cavity 21 of the busbar connector 2, and make the electrical connection of the two sets of conductive busbars 3 complete the electrical connection through the connection component 4; Step S5: Multiple sealing plates 5 are detachably installed on the busbar connector 2 to temporarily seal the assembly cavity 21. The sealing plate 5 at the top of the busbar connector 2 is provided with an injection hole 51, through which liquid sealant is injected into the assembly cavity 21. Step S6: After the liquid sealant has cured and formed a sealing colloid in the assembly cavity 21, remove the sealing plate 5.

[0043] The sealing colloid completely fills the assembly cavity 21, and the sealing colloid is seamlessly bonded to the surface of the conductive busbar 3.

[0044] As an optional implementation, in step S2, when shielding and protecting the electrical connection portion reserved on the conductive busbar 3, high-temperature resistant tape is used for shielding. The high-temperature resistant tape can be one of polyimide tape, polytetrafluoroethylene tape, or high-temperature resistant PET tape.

[0045] Specifically, the epoxy resin insulating powder includes epoxy resin, epoxy resin curing agent, and electrical insulating filler, wherein the electrical insulating material includes at least one of silica powder and mica powder.

[0046] Furthermore, in step S3, the curing process includes pre-curing and secondary curing: after the conductive busbar 3 is preheated, it is immersed in epoxy resin insulating powder. After the epoxy resin insulating powder adheres to the surface of the conductive busbar 3 except for the electrical connection overlap surface, it is first pre-cured in a curing oven to form an epoxy resin insulating layer. Then the shielding is removed, and it is placed in a curing oven for secondary curing to obtain a more stable and reliable epoxy resin insulating layer.

[0047] The preheating temperature of the conductive busbar 3 is 180-220℃, the preheating time is 20-30 min, the pre-curing temperature is 200-220℃, the pre-curing time is 20-30 min, the secondary curing temperature is 240℃-260℃, and the re-curing time is 40-50 min. Specifically, in this embodiment, the preheating temperature of the conductive busbar is 200℃, the preheating time is 20 min, the pre-curing temperature is 200℃, the pre-curing time is 20 min, the secondary curing temperature is 250℃, and the re-curing time is 40 min.

[0048] Further, in step S4, the electrical connection parts of the two sets of conductive busbars 3 that have completed epoxy insulation layer treatment are aligned with each other, and the electrical connection parts of the two sets of conductive busbars 3 are electrically connected through the composite connecting plate 41. Then, the first housing 22 and the second housing 23 of the busbar connector 2 are connected together through the first end plate 24 and the second end plate 25 to form an assembly cavity 21. Then, the fastener 42 is passed through the through hole of the first end plate 24, the through hole on the composite connecting plate 41, and the through hole of the second end plate 25 in sequence. The locking member 43 is screwed into the beginning of the first end plate 24 and the end of the second end plate 25. By tightening the locking member 43, the first end plate 24 and the second end plate 25 are pressed against each other, thereby firmly pressing the composite connecting plate 41 sandwiched therein, thereby realizing the electrical connection between the two sets of conductive busbars 3, and preparing for subsequent potting and sealing.

[0049] Specifically, the composite connection plate 41 has a multi-layer press-fit structure, consisting of an upper conductive layer, an intermediate insulating layer, and a lower conductive layer, which are bonded together as a single plate through a hot-pressing process. The upper and lower conductive layers are made of copper plates or copper alloy plates; the intermediate insulating layer is made of epoxy resin board, mica board, or polytetrafluoroethylene board. This structure allows the composite connection plate 41 to form insulation along its thickness, effectively preventing phase-to-phase short circuits when multiple composite connection plates 41 are installed side-by-side to connect multi-phase busbars.

[0050] Furthermore, in step S5, sealing plates 5 are detachably installed on the top and bottom of the busbar connector 2 to temporarily seal the assembly cavity 21. The sealing plate 5 on the top of the busbar connector 2 is provided with at least one glue injection hole 51.

[0051] In order to ensure that the liquid sealant can fully fill the assembly cavity 21 during injection and form a sealant with excellent comprehensive properties such as sealing, flame retardancy, thermal conductivity and mechanical strength after curing, the liquid sealant consists of 100 parts of insulating resin matrix, 150-200 parts of thermally conductive insulating filler, 20-50 parts of curing agent and 2-10 parts of additives.

[0052] The insulating resin matrix is ​​any one of silicone resin, epoxy resin, and polyurethane resin. The thermally conductive insulating filler includes aluminum nitride powder and flake alumina powder that have been surface-treated with a silane coupling agent. The flake alumina powder accounts for 5% to 20% of the total mass of the thermally conductive insulating filler.

[0053] In a preferred embodiment, the liquid sealant formulation, by weight, comprises: Insulating resin matrix: 100 parts of bisphenol A type epoxy resin; Thermally conductive and insulating filler (175 parts): 150 parts of aluminum nitride powder surface-treated with silane coupling agent, and 25 parts of flake alumina powder surface-treated with silane coupling agent. The silane coupling agent used is γ-aminopropyltriethoxysilane (KH-550), and KH-550 accounts for 1% of the total mass of the thermally conductive and insulating filler.

[0054] Curing agent: 35 parts of modified cycloaliphatic amine curing agent.

[0055] Additives: 2 parts fumed silica, 3 parts benzyl glycidyl ether.

[0056] In this preferred embodiment, the thermal conductivity of the liquid sealant formed by the above-described formulation can reach 1.15-1.20 W / (m·K), significantly higher than that of conventional insulating sealants; the volume resistivity is greater than 1.0 × 10⁻⁶. 15 Ω·cm ensures long-term electrical safety.

[0057] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A sealing process for a busbar trunking connector, characterized in that: Includes the following steps: Step S1: Provide multiple conductive busbars and perform surface cleaning treatment on the conductive busbars; Step S2: Shield and protect the electrical connection portion reserved on the conductive busbar; Step S3: Preheat the conductive bus from step S2, then immerse it in epoxy resin insulating powder, so that the epoxy resin insulating powder adheres to the surface of the conductive bus except for the electrical connection part, then perform curing treatment to form an epoxy resin insulating layer on the surface, and remove the shielding of the electrical connection part. Step S4: Place the two sets of conductive busbars processed in step S3 into the assembly cavity of the busbar connector, and make the electrical connection parts of the two sets of conductive busbars electrically connected through the connection assembly; Step S5: Multiple sealing plates are detachably installed on the busbar connector to temporarily seal the assembly cavity. The sealing plate at the top of the busbar connector is provided with an injection hole, through which liquid sealant is injected into the assembly cavity. Step S6: After the liquid sealant has cured and formed a sealing colloid in the assembly cavity, remove the sealing plate; Specifically, steps S1-S3 are the insulation and waterproofing process for the conductive busbar, and steps S4-S6 are the potting and waterproofing process for the busbar trunking connector.

2. The sealing process for a busbar trunking connector according to claim 1, characterized in that: In step S3, the curing process includes pre-curing and secondary curing: after the epoxy resin insulating powder is attached to the surface of the conductive busbar except for the electrical connection overlap surface, pre-curing is performed first to form the epoxy resin insulating layer, then the shielding is removed, and secondary curing is performed.

3. The sealing process for a busbar trunking connector according to claim 1, characterized in that: In step S3, the preheating temperature is 180-220℃, the preheating time is 20-30 min, the pre-curing temperature is 200-220℃, the pre-curing time is 20-30 min, the secondary curing temperature is 240℃-260℃, and the re-curing time is 40-50 min.

4. The sealing process for a busbar trunking connector according to claim 1, characterized in that: In step S5, the liquid sealant comprises 100 parts of insulating resin matrix, 150-200 parts of thermally conductive insulating filler, 20-50 parts of curing agent, and 2-10 parts of additives.

5. The sealing process for a busbar trunking connector according to claim 4, characterized in that: The insulating resin matrix is ​​any one of silicone resin, epoxy resin, and polyurethane resin. The thermally conductive insulating filler includes aluminum nitride powder and flake alumina powder that have been surface-treated with a silane coupling agent. The flake alumina powder accounts for 5% to 20% of the total mass of the thermally conductive insulating filler.

6. The sealing process for a busbar trunking connector according to claim 1, characterized in that: The epoxy resin insulating powder comprises epoxy resin, epoxy resin curing agent, and electrical insulating filler, wherein the electrical insulating material comprises at least one of silica powder and mica powder.

7. The sealing process for a busbar trunking connector according to claim 1, characterized in that: In step S4, the connecting assembly includes at least one composite connecting plate and fasteners. The composite connecting plate is disposed between the electrical connection parts of the two sets of conductive busbars to achieve electrical connection, and the fasteners fix the composite connecting plate to the electrical connection parts of the two sets of conductive busbars.

8. The sealing process for a busbar trunking connector according to claim 7, characterized in that: The composite connecting plate is an integral plate consisting of an upper conductive layer, a middle insulating layer, and a lower conductive layer, which are solidified by a hot pressing process. The upper and lower conductive layers are made of copper plates or copper alloy plates, and the middle insulating layer is made of epoxy resin plates, mica plates, or polytetrafluoroethylene plates.

9. The sealing process for a busbar trunking connector according to claim 7, characterized in that: The busbar connector includes a first housing, a second housing, and a first end plate and a second end plate connecting the first housing and the second housing. The first housing, the first end plate, the second housing, and the second end plate together enclose the assembly cavity. The fastener passes through the first end plate, the composite connecting plate, and the second end plate in sequence, and the fastener is fixed at both ends on the first end plate and the second end plate by a locking member, thereby pressing and fixing the composite connecting plate to the electrical connection part of the two sets of conductive busbars.

10. The sealing process for a busbar trunking connector according to claim 7, characterized in that: In step S6, the sealing colloid completely fills the assembly cavity, and the sealing colloid is seamlessly bonded to the surface of the conductive busbar.

11. A sealing structure for a busbar trunking connector, manufactured using the sealing process described in any one of claims 1 to 10, characterized in that: The device includes a busbar connector and two sets of conductive bars. The busbar connector has an assembly cavity, and the two sets of conductive bars are inserted into the assembly cavity. The two sets of conductive bars are electrically connected through a connecting assembly. Except for the electrical connection part, the surface of the conductive bars is covered with an epoxy resin insulating layer. The assembly cavity is filled with a sealing colloid.

12. A busbar trunking system, characterized in that, It includes the busbar trunking connector sealing structure as described in claim 11.

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