Automatic copper bar insulating rubber coating device

Abstract

This invention relates to the field of copper busbar insulation coating technology and discloses an automatic copper busbar insulation coating device, comprising: a dip-coating tank for containing dip-coating liquid; a hanging frame movably mounted above the dip-coating tank; at least one clamping unit mounted on the hanging frame for clamping the end of the copper busbar body, the clamping unit including a first clamping member and a second clamping member disposed opposite to each other, which can open and close relative to each other; and a composite sealing layer disposed on the inner surfaces of the first clamping member and the second clamping member for forming a seal with the surface of the copper busbar body in the clamped state. This invention mechanically shields the end of the copper busbar before dip-coating by the clamping unit, leaving the end area uncovered after dip-coating, completely eliminating the manual cutting and adhesive removal process, avoiding quality problems such as incomplete or excessive cutting, and significantly improving production efficiency and product consistency.

Description

Technical Field

[0001] This invention relates to the field of copper busbar insulation coating technology, and more specifically, to a device and process for automatically shielding the end connection holes and end face areas of copper busbars during the copper busbar dip coating process. Background Technology

[0002] The copper busbar is a flat, elongated conductive component with connection holes at both ends for electrical connections. In the PVC coating process, the copper busbar is suspended from a hook via the end connection holes, preheated, and then immersed in a PVC coating solution. After curing, it forms an insulating layer. After curing, the insulating layer around the end connection holes and end face of the copper busbar needs to be removed; otherwise, it will affect conductive contact and bolt installation.

[0003] Currently, this removal process is completed manually using a hand-held cutting tool, which presents the following problems: Unstable cutting quality: Manual cutting makes it difficult to ensure that the edges of the rubber are straight, and it is easy to cut incompletely (residual rubber affects conductivity) or cut too deep (damages the copper busbar substrate), which directly affects the electrical performance of the product; Low production efficiency: Both ends of each copper busbar need to be processed, which becomes a bottleneck in the production line during mass production and restricts the overall capacity. Safety hazard: Workers carrying sharp knives while operating on suspended copper busbars are prone to cuts and injuries.

[0004] Existing technologies also include solutions that add shielding devices to both ends of the copper busbar, but these solutions suffer from insufficient sealing, allowing the coating liquid to seep into the shielded area. Furthermore, in the coating process, it is generally believed that the shielding device and the copper busbar must maintain a "static tight fit," and the sealing material should be as "inert" as possible, not undergoing significant changes at high temperatures; otherwise, it may lead to seal failure or adhesion.

[0005] However, in mass dip-coating production, there is a long-neglected but real technical problem: sealing failure caused by thermal expansion mismatch, particularly with copper busbars (copper, with a thermal expansion coefficient of approximately 16.5 × 10⁻⁶). -6 / K) and metal shield (steel, coefficient of thermal expansion approximately 11.5 × 10) -6 / K) The expansion amounts of the two at high temperatures during dip coating are different. During the heating process, a micron-level gap expansion will occur between them. The dip coating liquid can penetrate into this gap under pressure. Traditional sealing methods cannot dynamically compensate for this thermal expansion difference, resulting in shielding failure.

[0006] Furthermore, in traditional thinking, high-temperature deformation and sealing reliability are considered contradictory. Therefore, there is an urgent need for an automatic copper busbar insulation coating device and process that can dynamically compensate for differences in thermal expansion and achieve adaptive sealing at high temperatures. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of existing technologies, such as the need for manual removal of the end rubber after copper busbar dip coating, low efficiency and unstable quality, and the inability of existing shielding schemes to solve the sealing failure caused by thermal expansion mismatch. The invention provides an automatic copper busbar insulation rubber coating device and process that can achieve automatic end shielding, adaptive sealing at high temperatures, and no need for subsequent processing.

[0008] The present invention provides an automatic copper busbar insulation coating device, comprising: A dip-coating tank is used to hold the dip-coating solution; The hanging bracket is vertically and adjustablely mounted above the dip-coating tank; At least one clamping unit is mounted on the bracket for clamping the end of the copper busbar body. The clamping unit includes a first clamping member and a second clamping member arranged opposite to each other, which can open and close relative to each other. A composite sealing layer is disposed on the inner surface of the first clamping member and the second clamping member, and is used to form a seal by adhering to the surface of the copper busbar body in the clamping state. The composite sealing layer includes a first functional layer that softens at high temperature and a second functional layer that expands in volume at high temperature. When the second functional layer expands at high temperature, it applies a compressive force to the first functional layer, so that the first functional layer dynamically adheres to the surface of the copper busbar body.

[0009] As a further optimization of the present invention, the composite sealing layer further includes a constraint layer, which is disposed on the outside of the second functional layer and is used to constrain the expansion direction of the second functional layer.

[0010] As a further optimization of the present invention, the constraint layer is a porous metal mesh layer.

[0011] As a further optimization of the present invention, the second functional layer is a microporous foamed elastomer layer, in which a low-boiling-point liquid is sealed within the micropores.

[0012] As a further optimization of the present invention, the clamping unit also includes a sealing post adapted to the connection hole at the end of the copper busbar body, for inserting into the connection hole to form a seal.

[0013] As a further optimization of the present invention, a sealing ring is also included, which is sleeved on the copper busbar body and is used to seal the gap between the end face of the clamping unit and the copper busbar body.

[0014] As a further optimization of the present invention, the sealing ring has a first sealing lip and a second sealing lip, forming a bidirectional sealing structure.

[0015] As a further optimization of the present invention, a clamping status indication mechanism is also included, which is used to issue an indication signal when the clamping unit is fully closed.

[0016] As a further optimization of the present invention, it also includes a buffer cavity connected to the second functional layer for absorbing overpressure when the second functional layer expands.

[0017] As a further optimization of the present invention, a piston and an elastic reset member are provided inside the buffer cavity.

[0018] A process for preparing a composite sealing layer for an automatic copper busbar insulation coating device, comprising the following steps: Step 1: Molding the heat-softening rubber material to form the first functional layer; Step 2: Place the first functional layer in the mold, spread the foaming agent on it, and pre-press it under conditions below the foaming temperature to make the first functional layer and the pre-foamed layer initially bonded together. Step 3: Heat the pre-formed composite to the foaming temperature to decompose the foaming agent and generate micropores, while simultaneously cross-linking and shaping the foamable elastomer to form a second functional layer with a microporous structure, and the first functional layer and the second functional layer are integrated into one. Step 4: Composite constraint layer on the outer surface of the second functional layer; Step 5: Inject the low-boiling-point liquid into the micropores of the second functional layer; Step 6: Seal the micropore openings on the surface of the second functional layer to prevent leakage of low-boiling-point liquids.

[0019] As a further optimization of the present invention, in step four, after coating the surface of the second functional layer with an adhesive, a porous metal mesh is laid out, and hot pressing is used to embed the metal mesh into the surface of the second functional layer.

[0020] As a further optimization of the present invention, in step three, a segmented heating method is adopted: first, the temperature is heated to the decomposition temperature of the foaming agent at a first heating rate and kept at the temperature to allow the micropores to grow fully; then, the temperature is heated to the crosslinking and setting temperature at a second heating rate and kept at the temperature to allow the elastomer to solidify.

[0021] As a further optimization of the present invention, step five includes: placing the composite sealing layer in a vacuum environment to remove air from the micropores, injecting a low-boiling-point liquid under vacuum, and then introducing pressurized gas to allow the liquid to fully penetrate the micropores.

[0022] As a further optimization of the present invention, in step six, a breathable polymer coating is sprayed onto the surface of the composite sealing layer, or a fast-curing silicone sealant is used to seal the micropores of the surface openings.

[0023] The automatic copper busbar insulation coating device proposed in this invention has the following beneficial effects: 1. The copper busbar ends are mechanically shielded by the clamping unit before dip coating. After dip coating, the end area is not covered with glue, which completely eliminates the manual cutting and glue removal process, avoids quality problems such as incomplete cutting or cutting too deep, and greatly improves production efficiency and product consistency.

[0024] 2. By adopting a reverse thinking approach, the composite sealing layer is dynamically enhanced by utilizing the high-temperature environment of dip coating to induce controllable thermal deformation. This does not damage the seal but rather dynamically strengthens it. The second functional layer expands in volume at high temperature, applying a compressive force to the first functional layer. The first functional layer softens at high temperature, adapting to the microscopic irregularities on the surface of the copper busbar. The two work together to achieve a better sealing effect under the high temperature of dip coating, thus solving the problem of seal failure caused by thermal expansion mismatch.

[0025] 3. The composite sealing layer adopts a three-layer structure: a heat-softening fluororubber layer, a microporous foaming expansion driving layer, and a porous metal mesh constraint layer. The heat-softening layer softens and adheres at high temperatures, the expansion layer generates expansion pressure through liquid vaporization, and the constraint layer guides the expansion direction and enhances the structural strength. The three layers work together to achieve the counterintuitive characteristics of convenient installation at room temperature and automatic reinforcement at high temperatures.

[0026] 4. To address the issue of the microporous foaming expansion drive layer potentially failing due to overpressure caused by continuous expansion, a buffer chamber and piston mechanism are set up to form a pressure safety valve. At high temperatures, steam can enter the buffer chamber to stabilize the pressure within a safe range. During the cooling process, the pressure gradient reverses, and steam and condensate can flow back to the micropores to achieve working fluid circulation, ensuring long-term stable operation of the device.

[0027] 5. The first and second sealing lips of the sealing ring form a bidirectional interference fit seal, which works in conjunction with the composite sealing layer to create multiple sealing barriers, ensuring that the plasticizing liquid cannot penetrate the shielded area.

[0028] 6. By coordinating the push rod and the indicator, a prompt signal is issued when the clamping part is fully closed, ensuring that the operator is aware of the clamping status and avoiding seal failure due to improper clamping.

[0029] 7. Multiple clamping units can be arranged linearly to clamp multiple copper busbars at once for batch dip coating treatment, greatly improving production efficiency.

[0030] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0031] Figure 1 This is a front view of the present invention. Figure 2 This is a schematic diagram of the assembly structure of the clamping unit and the end of the copper busbar body of the present invention; Figure 3 This is an exploded structural diagram of the clamping unit of the present invention; Figure 4 This is a schematic diagram of the first state of the clamping status indication structure in one embodiment of the present invention; Figure 5 This is a schematic diagram of the second state of the clamping state indication structure in one embodiment of the present invention; Figure 6 This is a schematic cross-sectional view of the sealing ring of the present invention; Figure 7 This is a schematic cross-sectional view of the composite sealing layer of the present invention; Figure 8 This is a schematic diagram of the internal buffer cavity of the fixed cylinder of the present invention.

[0032] Figure Descriptions: 1. Dip-coated box; 2. Hanger; 3. Hanging rod; 4. Pad; 5. First clamping component; 6. Second clamping component; 7. Copper busbar body; 8. Lifting rod; 9. Composite sealing layer; 91. First functional layer; 92. Second functional layer; 93. Constraint layer; 10. Sealing column; 11. Fixing cylinder; 12. Protective cover; 13. Top rod; 14. Elastic element; 141. Fixing ring; 142. First spring; 15. Indicator; 16. Pad; 17. Sealing ring; 18. First sealing lip; 19. Second sealing lip; 20. Rounded chamfer; 21. Piston; 22. Second spring; 23. Pressure transmission channel. Detailed Implementation

[0033] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0034] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0035] Please see Figures 1 to 8 The automatic copper busbar insulation rubber coating device proposed in this invention mainly includes a dip-coating box 1, a hanging frame 2, a clamping unit, and a composite sealing layer 9.

[0036] like Figure 1 As shown, in this embodiment, the dip-coating box 1 is filled with dip-coating liquid such as PVC dip-coating liquid. The hanging frame 2 is movably mounted above the opening of the dip-coating box 1. Two symmetrically distributed hanging rods 3 are installed at the bottom of the hanging frame 2. A pad 4 is installed at the lower end of the hanging rod 3. A first clamping member 5 located on the inner side of the lower end of the hanging rod 3 is installed on the pad 4. A second clamping member 6 that can be raised and lowered along the inner side of the hanging rod 3 is provided above the first clamping member 5. The two together constitute a clamping unit. The two ends of the copper busbar body 7 are clamped by adjacent clamping units respectively. There are multiple clamping units, which are linearly arranged at the bottom of the hanging frame 2, and multiple copper busbars can be clamped at the same time for batch processing.

[0037] The clamping unit is used to clamp the end of the copper busbar body 7 and shield the area to be protected, namely the connection hole and end face. Each clamping unit includes a first clamping member 5 and a second clamping member 6 arranged opposite to each other.

[0038] The boom 3 is equipped with a lifting mechanism (such as a cylinder, electric push rod or handwheel driven screw structure). A lifting rod 8 is installed on the movable end of the lifting mechanism. The other end of the lifting rod 8 extends to the inner side of the boom 3 and downward, and is fixedly connected to the second clamping member 6, thereby driving the second clamping member 6 to lift and lower, so as to achieve combined clamping with the first clamping member 5.

[0039] The first clamping member 5 and the second clamping member 6 are both L-shaped. The two L-shaped cavities are opposite each other, with their long sides parallel to each other and their short sides collinear and connected. The inner sidewalls of the L-shaped cavities are provided with composite sealing layers 9. The part of the copper busbar body 7 that needs to be shielded is placed in the L-shaped cavity, and the outer surface of the end is tightly fitted with the composite sealing layer 9.

[0040] like Figure 3 As shown, sealing posts 10 with matching diameters and corresponding positions to the connection holes at the ends of the copper busbar body 7 are installed on the upper and lower inner walls of the L-shaped cavity (i.e., the inner surfaces of the long sides of the two composite sealing layers 9). When clamping the ends of the copper busbar body 7, the upper and lower sealing posts 10 are inserted into and contact each other through the upper and lower openings of the connection hole, respectively. The sum of the heights of the two sealing posts 10 is consistent with the depth of the connection hole. The outer wall of the sealing post 10 is in close contact with the inner wall of the connection hole, thereby sealing the connection hole.

[0041] like Figure 8 As shown, the composite sealing layer 9 includes a first functional layer 91, a second functional layer 92, and a constraint layer 93 distributed sequentially from the inside to the outside; First functional layer 91: It adopts a heat-softening fluororubber layer with a Shore hardness of 70-80A at room temperature (25℃), which has sufficient rigidity for easy installation and positioning; the glass transition temperature is designed to be 60-70℃, and it begins to soften above this temperature; at 80-120℃, the hardness drops to 50-60A, exhibiting high elasticity; at a dip-coating working temperature of 150℃, the hardness drops to 30-40A, exhibiting a viscoelastic state, which can adaptively conform to the micro-unevenness of the surface of the copper busbar body 7 (it can completely fill when the roughness Ra≤3.2μm), and the thickness is 0.8-1.2mm.

[0042] The second functional layer 92: adopts a microporous foamed expansion driving layer, specifically microporous foamed silicone rubber, with a low-boiling-point driving liquid (such as ethanol, acetone, or a mixture of both) sealed inside; the pore size of the microporous structure is 20-50μm (closed-cell rate ≥90%), and the porosity is 40-60%; at room temperature, the liquid is in a liquid state and has no expansion force; at 80-150℃, the liquid vaporizes, and the volume expands by about 200-500 times, and the pressure inside the pores increases sharply, generating expansion force; Expansion performance parameters, taking ethanol as an example: Constraint layer 93: A porous metal mesh constraint layer (stainless steel woven mesh or perforated stainless steel strip); the wire diameter of the woven mesh is 0.15-0.25mm, and the aperture is 0.3-0.5mm; the thickness of the perforated strip is 0.2-0.3mm, the aperture is 0.5-1.0mm, and the opening rate is 30-50%; the function of the constraint layer is: ① to allow the second functional layer to expand towards the first functional layer and prevent it from expanding outward; ② to prevent the composite sealing layer from undergoing permanent deformation during repeated thermal cycling; ③ to act as a heat-conducting skeleton, accelerating the transfer of heat to the second functional layer and shortening the response time.

[0043] At room temperature, the composite sealing layer 9 remains rigid, facilitating installation and positioning; When the dip coating process starts heating and the temperature rises to above 80°C, the low-boiling-point liquid in the 92 micropores of the second functional layer vaporizes and expands rapidly, generating expansion pressure. The constraint layer 93 constrains the expansion direction to be inward (towards the first functional layer 91), and the expansion force presses the first functional layer 91 against the surface of the copper bus body 7. Meanwhile, the first functional layer 91 softens at high temperature and exhibits a viscoelastic state, adaptively conforming to the micro-unevenness of the copper busbar surface to form a tight seal; The higher the temperature, the more fully the softening occurs and the greater the expansion pressure, which actually enhances the sealing effect, perfectly solving the problem of sealing failure caused by thermal expansion mismatch.

[0044] To ensure that the clamping unit is fully closed in place, the present invention also includes a clamping status indication structure.

[0045] like Figure 5As shown, a protective cover 12 is installed on the upper end face of the second clamping member 6. A prompter 15 (preferably a buzzer or indicator light) is installed on the top of the inner cavity of the protective cover 12. The second clamping member 6 has a cavity inside and is fitted with a vertically arranged push rod 13. The upper end of the push rod 13 slides into the protective cover 12 and is fitted with a pad 16. The lower end of the push rod 13 slides through and extends to the bottom of the fixed cylinder 11.

[0046] The push rod 13 achieves vertical elastic extension and contraction through the elastic element 14 set in the cavity. The elastic element 14 includes a fixing ring 141 and a first spring 142 fitted on the push rod 13. The fixing ring 141 is fixedly connected to the push rod 13, and the two ends of the first spring 142 are fixedly connected to the lower end face of the fixing ring 141 and the bottom surface of the cavity, respectively.

[0047] When the second clamping member 6 moves downward and merges with the first clamping member 5, the sealing post 10 is inserted into the upper opening of the connecting hole of the copper busbar body 7. As the second clamping member 6 continues to move downward, the lower end of the push rod 13 contacts the upper end face of the lower fixed cylinder 11, causing the push rod 13 to move upward. The push rod 13 drives the fixed ring 141 and the pad 16 to move upward synchronously. The first spring 142 is stretched and deformed. When the two sealing posts 10 come into contact and the clamping is fully in place, the pad 16 comes into contact with the indicator 15, triggering the indicator 15 to issue a warning signal, indicating to the operator that the end of the copper busbar body 7 has been tightly clamped and the next dip coating operation can be carried out.

[0048] To further improve the sealing effect, the present invention also provides a sealing ring 17 at the end face joint of the clamping unit, such as... Figure 4 , Figure 6 As shown, before clamping and shielding the end of the copper busbar body 7, a sealing ring 17 is first fitted onto the end of the copper busbar body 7. The sealing ring 17 is moved outside the clamping range, and then clamping and shielding is performed. After clamping, the sealing ring 17 is placed against the end face joint of the lower clamping plate and the upper clamping plate.

[0049] The sealing ring 17 has a rectangular hole in the middle that matches the outer contour of the copper busbar body 7. The two end faces of the sealing ring 17 have a first sealing lip 18 and a second sealing lip 19 respectively. The first sealing lip 18 is located on one side near the end face joint, and the second sealing lip 19 is located on the other side. The inner ends of the two composite sealing layers 9 near the joint of the end face have rounded chamfers 20. The rounded chamfers 20 form a gap with the outer surface of the copper busbar body 7. The first sealing lip 18 is adapted to the shape of the gap and is tightly inserted to achieve an interference fit seal. The second sealing lip 19 on the other side also deforms and is tightly attached to the outer wall of the copper busbar body 7 to achieve a bidirectional interference fit seal. The first sealing lip 18 and the second sealing lip 19 are both made of high temperature resistant rubber. After fatigue, the sealing ring 17 can be replaced as a whole.

[0050] To address the potential failure of the microporous foaming expansion drive layer due to overpressure caused by continuous expansion, this invention incorporates a buffer chamber as a pressure safety valve. Figure 7 As shown, the interior of the fixed cylinder 11 is hollow to form a buffer cavity. A piston 21 and a second spring 22 are provided in the buffer cavity. The piston 21 is interference-fitted with the inner wall of the fixed cylinder 11. The end face of the piston 21 away from the microporous foaming expansion driving layer is connected to the inner wall of the free end of the fixed cylinder 11 through the second spring 22. The outer wall of the fixed cylinder 11 that contacts the composite sealing layer 9 has a pressure transmission channel 23 that communicates with the microporous foaming expansion driving layer 92. The pressure transmission channel 23 is sealed by a porous stainless steel plug with a capillary structure. The working principle is as follows: Heating stage: When the temperature rises above 80℃, the liquid ethanol in the micropores vaporizes and expands in volume, generating a vapor pressure (0.8-1.0MPa). The high-pressure vapor enters the buffer chamber through the porous stainless steel plug, pushing the piston 21 to move and compressing the second spring 22. The volume of the buffer chamber increases, stabilizing the pressure at 0.5-0.8MPa and avoiding overpressure. Cooling stage: As the temperature drops, the vapor in the micropores rapidly condenses into liquid, the pressure drops sharply and even forms a negative pressure, while the pressure in the buffer chamber drops more slowly. When the pressure in the buffer chamber is higher than the pressure in the expansion layer, the pressure gradient reverses, the high-pressure vapor in the buffer chamber flows back to the expansion layer, the temperature drops further, and the condensed liquid ethanol is forced back into the micropores, completing the working fluid cycle.

[0051] Reset: The piston 21 returns to its original position under the push of the second spring 22, and the system returns to its initial state at room temperature.

[0052] Throughout the process, ethanol circulates continuously within the sealed system without loss. The porous stainless steel plug plays a crucial role in selective permeability: allowing vapor to pass through at high temperatures and preventing liquid loss at room temperature, thus achieving automated management of sealing enhancement and media circulation.

[0053] The working process of this invention is as follows: 1. Clamping and shielding steps: Place the end of the copper busbar body 7 between the first clamping member 5 and the second clamping member 6; A sealing ring 17 is fitted onto the copper busbar body 7 and moved outside the clamping range; Drive the lifting mechanism to lower the second clamping member 6 and close it with the first clamping member 5; The sealing post 10 is inserted into the connection hole, and the composite sealing layer 9 is attached to the surface of the copper busbar; When the clamping is fully in place, the push rod 13 triggers the indicator 15 to issue a prompt. Push the sealing ring 17 to the end face joint so that the first sealing lip 18 is inserted into the rounded chamfered gap to complete the double seal.

[0054] 2. Dip coating step: Lower the bracket 2 so that the copper busbar body 7 is immersed in the plasticizing solution in the plasticizing tank 1; Heat the dip coating solution to approximately 150°C (working temperature) and maintain it for the predetermined time. During this process, the composite sealing layer 9 undergoes a dynamic response: the first functional layer 91 softens, the second functional layer 92 expands, and a compressive force is applied to the first functional layer 91, thereby enhancing the sealing effect; The buffer chamber absorbs overpressure and maintains stable pressure.

[0055] 3. Curing Steps: Raise the bracket 2 so that the copper busbar body 7 is removed from the dip coating liquid; Move rack 2 into the oven for drying and curing; During the curing process, the composite sealing layer 9 gradually regains its rigidity as the temperature decreases, and the working fluid flows back into the micropores.

[0056] 4. Demolding steps: After curing and cooling, open the clamping unit and remove the copper busbar body 7; The shielded area at the 7th end of the copper busbar body is not covered with rubber and requires no further processing.

[0057] It should be noted that the components or structural surfaces in the above-mentioned device that need to be immersed in the dip coating have a non-stick coating, such as a Teflon coating.

[0058] The composite sealing layer 9 is prepared using a layered molding + secondary vulcanization + liquid injection process, with the specific steps as follows: First functional layer compression molding: Use precision-machined steel mold with cavity surface roughness Ra≤0.4μm; the rubber compound formula is 100 parts of fluororubber raw rubber, 15-20 parts of low molecular weight plasticizer, 2-3 parts of heat-sensitive crosslinking regulator, and 3-5 parts of vulcanizing agent; the molding temperature is 160-170℃, the pressure is 10-15MPa, and the time is 5-8 minutes.

[0059] First functional layer and second functional layer composite preforming: Place the molded first functional layer at the bottom of the second functional layer molding mold, lay unfoamed silicone rubber premix (containing foaming agent and liquid microcapsules), and preform at 80-90℃ and 2-3MPa for 3-5 minutes.

[0060] Microporous foaming treatment: Place in a foaming oven and bring the temperature from room temperature to 120℃ (5℃ / min) to decompose the foaming agent. Keep the temperature at 120℃ for 20-30 minutes to allow micropores to grow. Then, bring the temperature from 120℃ to 180℃ (3℃ / min) to allow the silicone rubber to crosslink and set. Keep the temperature at 180℃ for 15 minutes.

[0061] Constraint layer composite: Coat the surface of the foamed second functional layer with silicone rubber adhesive, lay down a metal mesh, and hot press at 150℃ and 2-3MPa for 5 minutes.

[0062] Secondary vulcanization and setting: Place in an oven and treat at 200℃ for 4 hours.

[0063] Low-boiling-point liquid infusion and sealing: Place in a vacuum infusion tank, evacuate to 10-50 Pa and maintain for 30 minutes, inject liquid under vacuum, pressurize to 0.5-0.8 MPa and maintain for 1-2 hours, remove and wipe off surface residue, and spray with a breathable polymer coating to seal the pores.

[0064] The scope of protection of this invention is not limited to the specific embodiments described above. Several typical variations are listed below: Variation 1: Replacement of clamping component shape The first and second clamping components are not limited to L-shapes; they can also be U-shaped, C-shaped, arc-shaped, or other shapes to accommodate copper busbars with different cross-sectional shapes.

[0065] Variation 2: Replacement of the driving method The lifting mechanism is not limited to cylinders and electric push rods, but can also adopt various linear drive forms such as hydraulic cylinders, lead screws and nuts, and gear racks.

[0066] Variation 3: Replacement of composite sealing layer materials The first functional layer is not limited to fluororubber, but can also be made of high-temperature resistant elastomers such as silicone rubber and EPDM rubber; the second functional layer is not limited to silicone rubber, but can also be made of other foamable elastomers.

[0067] Variation 4: Substitution of low-boiling-point liquids The liquid used for sealing is not limited to ethanol and acetone; other low-boiling-point liquids or mixtures with boiling points between 50-100°C can also be used to adjust the expansion temperature.

[0068] Variant 5: Replacement of the buffer cavity structure The buffer chamber is not limited to piston type; it can also adopt elastic volume structure such as diaphragm type or airbag type.

[0069] Variation 6: Expansion of Application Areas This invention is not only applicable to copper busbar dip coating, but can also be extended to other metal workpiece dip coating, dip-coating, and impregnation processes that require partial masking.

[0070] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automatic copper busbar insulation sheath wrapping device, comprising: A dip-coating tank is used to hold the dip-coating solution; The hanging bracket is vertically and adjustablely mounted above the dip-coating tank; Its characteristic is that it further includes: At least one clamping unit is mounted on the bracket for clamping the end of the copper busbar body. The clamping unit includes a first clamping member and a second clamping member arranged opposite to each other, which can open and close relative to each other. A composite sealing layer is disposed on the inner surface of the first clamping member and the second clamping member, and is used to form a seal by adhering to the surface of the copper busbar body in the clamping state. The composite sealing layer includes a first functional layer that softens at high temperature and a second functional layer that expands in volume at high temperature. When the second functional layer expands at high temperature, it applies a compressive force to the first functional layer, so that the first functional layer dynamically adheres to the surface of the copper busbar body.

2. The automatic copper busbar insulation sheath wrapping device according to claim 1, characterized in that, The composite sealing layer also includes a constraint layer, which is disposed on the outside of the second functional layer and is used to constrain the expansion direction of the second functional layer.

3. The automatic copper busbar insulation sheathing device according to claim 2, characterized in that, The constraint layer is a porous metal mesh layer.

4. The automatic copper busbar insulation sheath wrapping device according to claim 1, characterized in that, The second functional layer is a microporous foamed elastomer layer, in which low-boiling-point liquid is sealed within the micropores.

5. The automatic copper busbar insulation sheathing device according to claim 1, characterized in that, The clamping unit also includes a sealing post adapted to the connection hole at the end of the copper busbar body, for inserting into the connection hole to form a seal.

6. The automatic copper busbar insulation sheathing device according to claim 1, characterized in that, It also includes a sealing ring, which is sleeved on the copper busbar body to seal the gap between the end face of the clamping unit and the copper busbar body.

7. The automatic copper busbar insulation sheathing device according to claim 6, characterized in that, The sealing ring has a first sealing lip and a second sealing lip, forming a bidirectional sealing structure.

8. A process for preparing a composite sealing layer for an automatic copper busbar insulation coating device, used to prepare the composite sealing layer as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1: Molding the heat-softening rubber material to form the first functional layer; Step 2: Place the first functional layer in the mold, spread the foaming agent on it, and pre-press it under conditions below the foaming temperature to make the first functional layer and the pre-foamed layer initially bonded together. Step 3: Heat the pre-formed composite to the foaming temperature to decompose the foaming agent and generate micropores, while simultaneously cross-linking and shaping the foamable elastomer to form a second functional layer with a microporous structure, and the first functional layer and the second functional layer are integrated into one. Step 4: Composite constraint layer on the outer surface of the second functional layer; Step 5: Inject the low-boiling-point liquid into the micropores of the second functional layer; Step 6: Seal the micropore openings on the surface of the second functional layer to prevent leakage of low-boiling-point liquids.

9. The composite sealing layer preparation process according to claim 8, characterized in that, In step four, after coating the surface of the second functional layer with an adhesive, a porous metal mesh is laid out, and hot pressing is used to embed the metal mesh into the surface of the second functional layer.

10. The composite sealing layer preparation process according to claim 8, characterized in that, Step five includes: placing the composite sealing layer in a vacuum environment to remove air from the micropores, injecting a low-boiling-point liquid under vacuum, and then introducing pressurized gas to allow the liquid to fully penetrate the micropores.

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