Anti-short-circuit structure of conductive bar with double-sided adhesive insulating plate

Abstract

The application relates to the technical field of insulation protection of conductive connecting rows, and discloses a short-circuit prevention structure of a conductive row with double-sided adhesive insulating plates, which comprises a first conductor, a second conductor and an insulating plate; the first conductor and the second conductor are oppositely arranged, the short-circuit prevention structure of the conductive row with double-sided adhesive insulating plates is arranged by using the physical separation of the insulating plate between two conductive rows, a stable and continuous insulating barrier layer can be formed between adjacent conductive rows, even if the insulating layer coated outside the conductive row is damaged, falls off or fails due to long-term friction, extrusion or external force, the insulating plate can still effectively prevent the direct contact of the metal matrix of the two conductive rows, completely blocks the abnormal current conduction path, and structurally prevents the short-circuit phenomenon from occurring, so that the operation safety and stability of the conductive assembly in dense installation and narrow space are obviously improved, and the whole electrical system can continuously and reliably work.

Description

Technical Field

[0001] This invention relates to the field of conductive connector insulation protection technology, specifically a short-circuit protection structure for conductive connectors with double-sided adhesive-backed insulating boards. Background Technology

[0002] Copper and aluminum busbars, as excellent electrical and thermal conductive components, possess good ductility and processing performance, and are widely used in conductive connection scenarios in electrical equipment, machinery manufacturing, new energy, and automobiles. In various electrical devices, busbars are often assembled in a compact layout to meet the design requirements of equipment miniaturization and integration, and are a core basic component for achieving stable power transmission.

[0003] However, in densely installed environments, the installation gap between adjacent busbars is small, making them prone to mutual friction and compression during operation. This can lead to damage or detachment of the insulation layer covering the busbars. When the insulation layer fails, the metal substrates of adjacent busbars are directly exposed and come into contact with each other, causing current conduction and ultimately resulting in a short circuit. This affects the safe operation of the equipment and limits the application range of copper and aluminum busbars in highly integrated scenarios.

[0004] Therefore, a short-circuit protection structure for conductive busbars with double-sided adhesive backing is proposed to solve the aforementioned problems. Summary of the Invention

[0005] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a short-circuit protection structure for conductive busbars with double-sided adhesive backing insulation boards. This solves the problem that the insulation layer of adjacent conductive busbars may fail due to small installation gaps and mutual friction, leading to direct contact and short-circuit faults in the metal substrate.

[0006] Technical solution To achieve the above objectives, the present invention provides the following technical solution: a conductive short-circuit protection structure with a double-sided adhesive backing insulating board, comprising a first conductor, a second conductor, and an insulating board; the first conductor and the second conductor are arranged opposite to each other, the insulating board is disposed between the first conductor and the second conductor, one surface of the insulating board is connected to the first conductor, and the other surface of the insulating board is connected to the second conductor, the insulating board is used to separate the first conductor and the second conductor to avoid direct contact between them.

[0007] Preferably, the first conductor is a conductive bus with an external insulating layer, the first conductor is a copper conductive bus, the insulating layer of the first conductor covers its entire outer surface, and the insulating plate is attached to the insulating layer of the first conductor.

[0008] Preferably, the second conductor is a conductive busbar with an external insulating layer, the second conductor is made of aluminum, the insulating layer of the second conductor completely covers its conductive substrate, and the insulating plate is tightly attached to the insulating layer of the second conductor.

[0009] Preferably, the insulating board is made of epoxy resin glass cloth laminate, and the insulating board has rigid insulation support performance. The insulating board can withstand the assembly pressure of the first conductor and the second conductor without deformation.

[0010] Preferably, an adhesive layer is provided on both sides of the insulating board, and the adhesive layer uniformly covers the two sides of the bonding surface of the insulating board. The adhesive layer is used to realize the fixed connection between the insulating board and the first conductor and the second conductor.

[0011] Preferably, the adhesive layer is a double-sided adhesive layer, which is integrally integrated with the main structure of the insulating board, and can be directly bonded and fixed to the conductor surface.

[0012] Preferably, the length, width, and thickness of the insulating plate are all adjustable, and the dimensions of the insulating plate are set to match the external dimensions of the first conductor and the second conductor.

[0013] Preferably, the first conductor, the second conductor, and the insulating plate are assembled to form an integral structure, and the insulating plate forms a continuous insulating barrier area between the first conductor and the second conductor.

[0014] Preferably, the first conductor and the second conductor are arranged parallel to each other, and the edge of the insulating plate does not extend beyond the edge range of the first conductor and the second conductor.

[0015] Beneficial effects Compared with the prior art, the present invention provides a short-circuit protection structure for conductive bars with double-sided adhesive-backed insulating boards, which has the following beneficial effects: 1. This short-circuit protection structure for conductive bars with double-sided adhesive backing utilizes the insulating plate to physically separate the two conductive bars, forming a stable and continuous insulating barrier layer between adjacent conductive bars. Even if the outer insulating layer of the conductive bars is damaged or falls off due to long-term friction, compression, or external force, the insulating plate can still effectively prevent direct contact between the metal substrates of the two conductive bars, completely blocking the abnormal current conduction path. This structurally eliminates the occurrence of short circuits, significantly improving the operational safety and stability of conductive components in densely installed and confined spaces, and ensuring the continuous and reliable operation of the entire electrical system.

[0016] 2. This short-circuit protection structure for the conductive busbar with double-sided adhesive backing allows for direct bonding using the self-adhesive backing of the insulation board. No secondary processing such as drilling, tapping, or welding is required, nor are additional fasteners like bolts, clips, or brackets needed. Assembly is simple and quick; simply align the insulation board to the bonding position for secure installation. This significantly simplifies the assembly process, reduces production time, and avoids damage to the conductive busbar itself during processing and assembly. The overall structure is more concise and compact, adaptable to the installation needs of various highly integrated devices, and offers greater practicality.

[0017] 3. This short-circuit protection structure for conductive busbars with double-sided adhesive backing allows for customized matching of the insulation board's length, width, and thickness. It can be flexibly adjusted according to the external dimensions, installation spacing, and layout of different models and specifications of copper or aluminum busbars. This enables precise adaptation to conductive components of various sizes and installation scenarios, eliminating the need for separate molds or structural redesigns for different products. This effectively improves product versatility and interchangeability, reduces R&D and manufacturing costs, and broadens the application scope of conductive busbars in multiple fields such as new energy, electrical equipment, and automotive electronic control. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of a conductive busbar with double-sided adhesive-backed insulating board for short circuit prevention proposed in this invention. Figure 2 This is a schematic diagram of the first conductor structure of a conductive busbar with a double-sided adhesive-backed insulating board for short circuit prevention proposed in this invention. Figure 3 This is a schematic diagram of the second conductor structure of a conductive busbar with a double-sided adhesive-backed insulating board for short circuit prevention proposed in this invention. Figure 4 This is a schematic diagram of a short-circuit protection structure for conductive bars with double-sided adhesive backing, as proposed in this invention. Figure 5 This is a schematic diagram of the combined structure of the conductive busbar short-circuit protection structure insulation board with double-sided adhesive backing and the adhesive layer proposed in this invention. Figure 6 This is a front view of the assembly structure of a conductive busbar with double-sided adhesive-backed insulating board for short circuit prevention proposed in this invention.

[0019] In the diagram: 1. First conductor; 2. Second conductor; 3. Insulating plate; 4. Adhesive layer. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 - Figure 6 As shown, a short-circuit protection structure for conductive busbars with double-sided adhesive backing includes a first conductor 1, a second conductor 2, and an insulating plate 3. The first conductor 1 and the second conductor 2 are arranged opposite to each other. The insulating plate 3 is disposed between the first conductor 1 and the second conductor 2. One surface of the insulating plate 3 is connected to the first conductor 1, and the other surface of the insulating plate 3 is connected to the second conductor 2. The insulating plate 3 is used to separate the first conductor 1 and the second conductor 2 to prevent them from directly contacting each other. The short-circuit protection structure for conductive components is achieved by pasting the insulating plate 3 between the two copper busbars. The insulating plate 3 is pasted to the upper and lower copper busbars with double-sided adhesive backing. By controlling the length, width, and thickness of the insulating plate 3, the two copper busbars are separated to prevent current conduction between the two copper busbars and short circuit when the insulation layer of the copper busbars is damaged. This solution has good insulation effect and can effectively prevent short circuits in conductive components. The processing flow of the short-circuit protection structure for conductive components is blanking → bending → removing the insulation layer → punching → assembly, which is simple and the precision is easy to control.

[0022] First, the first conductor 1 is a conductive bus with an external insulating layer. The first conductor 1 is made of copper and the insulating layer covers its entire outer surface. The insulating plate 3 is attached to the insulating layer of the first conductor 1. The first insulating protection structure is formed by the insulating layer completely covered by the first conductor 1 itself. With the tight attachment of the insulating plate 3 to the insulating layer of the first conductor 1, the metal substrate of the first conductor 1 is fully enclosed and protected. This effectively avoids the substrate of the first conductor 1 being exposed under friction, vibration and extrusion conditions, and significantly improves the initial insulation safety level and operational stability of the conductive component.

[0023] Secondly, the second conductor 2 is a conductive bus with an external insulating layer. The second conductor 2 is made of aluminum. The insulating layer of the second conductor 2 completely covers its conductive substrate. The insulating plate 3 is tightly attached to the insulating layer of the second conductor 2. The fully wrapped insulating layer of the second conductor 2 forms a basic insulating barrier. With the help of the strong adhesion between the insulating plate 3 and the insulating layer of the second conductor 2, the conductive substrate of the second conductor 2 is protected by double isolation. This prevents the second conductor 2 from directly contacting and conducting with adjacent conductors due to insulation layer damage during long-term operation, thereby reducing the risk of short circuit faults from the root.

[0024] Furthermore, the insulating board 3 is made of epoxy resin glass cloth laminate. The insulating board 3 has rigid insulation support performance. The insulating board 3 can withstand the assembly pressure of the first conductor 1 and the second conductor 2 without deformation. Through the structural characteristics of the insulating board 3 itself with high rigidity and high insulation strength, it can stably maintain the preset safe distance between the first conductor 1 and the second conductor 2, and avoid the two conductors from shrinking the distance, failing to fit or making local contact under assembly pressure and long-term vibration, so as to ensure that the insulation barrier is continuously reliable throughout the entire life cycle.

[0025] Furthermore, adhesive layers 4 are provided on both sides of the insulating board 3. The adhesive layers 4 uniformly cover the two sides of the insulating board 3. The adhesive layers 4 are used to achieve a fixed connection between the insulating board 3 and the first conductor 1 and the second conductor 2. By increasing the bonding area through the full-coverage adhesive layer 4, the insulating board 3 is firmly bonded to the two conductors, without shifting or falling off, thus ensuring the stability of the insulation separation position.

[0026] Furthermore, the adhesive layer 4 is a double-sided adhesive layer, which is integrally integrated with the main structure of the insulating board 3. The double-sided adhesive layer can be directly bonded and fixed to the conductor surface. Through the double-sided adhesive structure integrally formed by the adhesive layer 4 and the insulating board 3, the insulating board 3 can be quickly assembled with the first conductor 1 and the second conductor 2 without drilling, welding, or fasteners, which greatly simplifies the installation process. At the same time, it ensures high bonding strength, vibration resistance, and temperature change resistance, ensuring that the insulating board 3 will not warp, shift, or fall off for a long time.

[0027] Furthermore, the length, width, and thickness of the insulating plate 3 are all adjustable. The dimensions of the insulating plate 3 are matched and set according to the external dimensions of the first conductor 1 and the second conductor 2. Through the flexible customizable length, width, and thickness structure of the insulating plate 3, it is possible to achieve precise adaptation to the first conductor 1 and the second conductor 2 with different specifications, spacing, and layouts, fully cover the hazardous contact area, improve the structural versatility and interchangeability, reduce R&D and production costs, and adapt to confined spaces and high-density installation scenarios.

[0028] Furthermore, the first conductor 1, the second conductor 2, and the insulating plate 3 are assembled to form an integral structure. The insulating plate 3 forms a continuous insulating barrier area between the first conductor 1 and the second conductor 2. Through the seamless assembly structure of the first conductor 1, the second conductor 2, and the insulating plate 3, a continuous, complete, and unbroken insulating barrier is achieved, which completely blocks the abnormal current conduction path between the two conductors. Even if the outer insulation of the conductor is damaged, short circuits can still be prevented from occurring from a physical structure perspective.

[0029] Finally, the first conductor 1 and the second conductor 2 are arranged in parallel to each other, and the edge of the insulating plate 3 does not exceed the edge range of the first conductor 1 and the second conductor 2. Through the parallel and symmetrical arrangement of the first conductor 1 and the second conductor 2 and the size limiting structure of the insulating plate 3, the effect of uniform stress on the two conductors and consistent insulation distribution is achieved, avoiding local stress concentration and weak points in insulation. At the same time, it prevents the insulating plate 3 from extending outward and interfering with surrounding components, thereby improving the overall structural compactness, assembly safety and equipment integration.

[0030] Working principle: The short-circuit protection structure of this conductive pad with double-sided adhesive backing 3 uses rigid physical separation, double insulation protection, stable bonding and positioning, and size adaptive matching as its core working mechanism. Under various complex working conditions such as normal power transmission of conductive components, equipment vibration operation, insulation layer wear and damage, and external force extrusion and friction, it can continuously, stably and reliably achieve short-circuit protection, ensuring the safe operation of the electrical system.

[0031] This structure mainly consists of a first conductor 1, a second conductor 2, an insulating plate 3, and double-sided adhesive layers integrally formed on both sides of the insulating plate 3. During assembly, the insulating plate 3 is precisely placed between the opposite surfaces of the first conductor 1 and the second conductor 2. The double-sided adhesive layers on the upper and lower sides of the insulating plate 3 quickly adhere and press against the insulating surfaces of the first conductor 1 and the second conductor 2, respectively, thus stably clamping the insulating plate 3 between the two conductors. This forms an inseparable, gapless, and misaligned integral assembly structure with the first conductor 1 and the second conductor 2, achieving a reliable connection without the need for additional fasteners such as bolts, welding, or clips.

[0032] Both the first conductor 1 and the second conductor 2 are conductive busbars with complete external insulation layers. When normally energized, the first conductor 1 and the second conductor 2 each undertake the task of transmitting electrical energy. Their external insulation layers form the first insulation protection system, which can directly isolate the internal metal conductive substrate from the outside world, and at the same time prevent direct contact and current conduction between the two conductors, thus meeting the insulation safety requirements under normal conditions. During long-term operation of the equipment, due to factors such as compact installation space, continuous vibration of the equipment, mutual friction between conductors, and external squeezing and collision, the outer insulation layers of the first conductor 1 and the second conductor 2 are prone to local wear, scratch damage, aging and peeling, cracking and failure. Once the insulation layer fails, the metal matrix inside the conductor will be directly exposed. The metal matrix of two adjacent conductors can easily come into contact with each other, quickly forming an abnormal current path, which can lead to serious faults such as short circuits, arcing, and device burnout. When the first layer of insulation protection fails, the insulating plate 3 sandwiched between the two conductors immediately activates the second layer of insulation protection. With the excellent insulation performance, high mechanical strength, and rigid support structure of the epoxy resin glass cloth laminate itself, a stable, continuous, completely sealed, and impenetrable physical isolation layer is formed between the first conductor 1 and the second conductor 2. This forcibly maintains a safe insulation distance between the two conductors, completely blocking the current conduction path between the metal matrix from a physical structure perspective, preventing abnormal current crossflow, arc generation, and short circuit loop formation, and avoiding short circuit faults from the root. The insulating plate 3 maintains a high-strength and high-stability bond with the first conductor 1 and the second conductor 2 through the double-sided adhesive layer. It can withstand the external influences such as equipment vibration, micro-displacement, temperature changes, and humid and dusty environments for a long time, and will not experience problems such as loosening, slippage, warping, falling off, or breakage. It can maintain an effective separation state throughout the entire product life cycle. Meanwhile, the length, width, and thickness of the insulating plate 3 can be flexibly customized and adjusted according to the specifications, shape, and installation spacing of the first conductor 1 and the second conductor 2, ensuring that the insulating plate 3 completely covers all dangerous contact areas of the two conductors. Even in a small, dense, and highly integrated electrical assembly environment, it can still achieve full-area, no dead corners, and no omissions of insulation barrier, ensuring stable, safe, and uninterrupted power transmission of conductive components, and significantly improving the operational safety, stability, and durability of the entire electrical system.

[0033] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A short-circuit protection structure for conductive busbars with double-sided adhesive-backed insulating boards, characterized in that, It includes a first conductor (1), a second conductor (2), and an insulating plate (3); the first conductor (1) and the second conductor (2) are arranged opposite to each other, the insulating plate (3) is disposed between the first conductor (1) and the second conductor (2), one surface of the insulating plate (3) is connected to the first conductor (1), and the other surface of the insulating plate (3) is connected to the second conductor (2). The insulating plate (3) is used to separate the first conductor (1) and the second conductor (2) to avoid direct contact between them.

2. The short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 1, characterized in that: The first conductor (1) is a conductive bus with an external insulating layer. The first conductor (1) is made of copper. The insulating layer of the first conductor (1) covers its entire outer surface. The insulating plate (3) is attached to the insulating layer of the first conductor (1).

3. The short-circuit protection structure of a conductive busbar with double-sided adhesive-backed insulating board according to claim 1, characterized in that: The second conductor (2) is a conductive bus with an external insulating layer. The second conductor (2) is made of aluminum. The insulating layer of the second conductor (2) completely covers its conductive substrate. The insulating plate (3) is closely attached to the insulating layer of the second conductor (2).

4. The short-circuit protection structure of a conductive busbar with double-sided adhesive-backed insulating board according to claim 1, characterized in that: The insulating board (3) is made of epoxy resin glass cloth laminate. The insulating board (3) has rigid insulation support performance and can withstand the assembly pressure of the first conductor (1) and the second conductor (2) without deformation.

5. A short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 4, characterized in that: An adhesive layer (4) is provided on both sides of the insulating plate (3). The adhesive layer (4) evenly covers the two sides of the insulating plate (3) and is used to achieve a fixed connection between the insulating plate (3) and the first conductor (1) and the second conductor (2).

6. A short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 5, characterized in that: The adhesive layer (4) is a double-sided adhesive layer. The double-sided adhesive layer is integrally combined with the main structure of the insulating board (3). The double-sided adhesive layer can be directly bonded and fixed to the conductor surface.

7. A short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 1, characterized in that: The length, width and thickness of the insulating plate (3) are adjustable. The dimensions of the insulating plate (3) are set to match the external dimensions of the first conductor (1) and the second conductor (2).

8. A short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 1, characterized in that: The first conductor (1), the second conductor (2), and the insulating plate (3) are assembled to form an integral structure, and the insulating plate (3) forms a continuous insulating barrier area between the first conductor (1) and the second conductor (2).

9. A short-circuit protection structure for conductive strips with double-sided adhesive-backed insulating boards according to claim 1, characterized in that: The first conductor (1) and the second conductor (2) are arranged parallel to each other, and the edge of the insulating plate (3) does not exceed the edge range of the first conductor (1) and the second conductor (2).

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