A new production process of high-voltage aluminum strip for new energy vehicle charging assembly with shielding

Abstract

The application discloses a novel high-voltage aluminum bar production process for a new energy automobile charging assembly with a shielding function, and belongs to the technical field of new energy automobile high-voltage connecting piece production. The process comprises the following steps: S1, AL6101-T64 aluminum alloy ingots are selected and extruded into flat aluminum conductors with a thickness of 6.3 mm and a width of 35 mm, and the flat aluminum conductors are subjected to straightening, cleaning and drying treatment; S2, the flat aluminum conductors are fixed through positioning clamps; S3, a 90-type extruding machine is used to continuously extrude high-temperature nylon on the outer side of the flat aluminum conductors, and the high-temperature nylon is cooled and shaped to form a high-temperature-resistant nylon insulation layer; S4, a 90-type extruding machine is used to continuously extrude thermoplastic conductive resin on the outer side of the high-temperature-resistant nylon insulation layer, and the thermoplastic conductive resin is cooled and shaped to form a conductive resin shielding layer; and S5, an electrostatic spraying mode is used to coat a graphene shielding reinforcing layer on the surface of the conductive resin shielding layer, and the graphene shielding reinforcing layer is cured in an oven.

Description

Technical Field

[0001] This invention relates to the field of high-voltage connector manufacturing technology for new energy vehicles, specifically a new manufacturing process for high-voltage aluminum busbars used in shielded new energy vehicle charging assemblies. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the market has increasingly stringent requirements for the performance of high-voltage connectors for charging assemblies. They not only need to meet the core requirements of high current transmission, small space occupation, and light weight, but also need to have excellent anti-interference, high temperature resistance, fire resistance, and heat dissipation performance.

[0003] Currently, the installation of battery packs, motors, and electronic control equipment in new energy vehicles is becoming increasingly dense. Traditional connecting cables mostly use round wire structures. However, to ensure high current transmission capacity, traditional round wires require multi-strand conductor twisting, resulting in larger cable diameters and higher vertical space occupancy, making them unsuitable for dense installation environments. Furthermore, the high density of copper conductors makes traditional round wires heavy, increasing the overall vehicle load and hindering range improvement. In addition, the shielding structure of traditional round wires often uses braided shielding, which suffers from high porosity and discontinuous shielding, resulting in limited shielding effectiveness and difficulty in forming a complete electromagnetic shielding barrier. This fails to effectively resist electromagnetic radiation interference between dense electronic devices, thus affecting the stable operation of the charging system and other electronic devices in the vehicle. Therefore, there is an urgent need for a high-voltage connecting component manufacturing process that can adapt to dense installation environments, has a small footprint, is lightweight, and has excellent anti-interference performance, to solve the many problems caused by traditional round wires and meet the usage requirements of new energy vehicle charging assemblies. Summary of the Invention

[0004] The purpose of this invention is to provide a novel manufacturing process for high-voltage aluminum busbars used in shielded new energy vehicle charging assemblies, in order to solve the problems mentioned in the background art.

[0005] In view of the above problems, the technical solution proposed by the present invention is as follows:

[0006] A novel manufacturing process for high-voltage aluminum busbars used in shielded new energy vehicle charging assemblies, wherein the produced high-voltage aluminum busbar comprises, from the inside out, a flat aluminum conductor, a high-temperature resistant nylon insulation layer, a conductive resin shielding layer, a graphene shielding reinforcement layer, and a PVC outer insulation layer, including the following steps:

[0007] S1. AL6101-T64 aluminum alloy ingots are extruded into flat aluminum conductors with a thickness of 6.3mm and a width of 35mm, and then straightened, cleaned and dried.

[0008] S2. Fix the aluminum conductor using the positioning clamp;

[0009] S3. High-temperature nylon is continuously extruded and coated onto the outside of a flat aluminum conductor using a 90-type extruder, and then cooled and shaped to form a high-temperature resistant nylon insulation layer.

[0010] S4. A 90-type extruder is used to continuously extrude thermoplastic conductive resin onto the outside of a high-temperature resistant nylon insulation layer, which is then cooled and shaped to form a conductive resin shielding layer.

[0011] S5. A graphene shielding reinforcement layer is coated onto the surface of the conductive resin shielding layer using electrostatic spraying and then cured in an oven.

[0012] S6. A flame-retardant PVC is continuously extruded and coated onto the outside of the graphene shielding reinforcement layer using a 120-type extruder, and then cooled and shaped to form a PVC outer insulation layer.

[0013] S7. Cut the continuously formed high-pressure aluminum busbar, peel off the ends, bend it into shape, punch holes in the conductor, and package it into warehouse after passing the inspection.

[0014] Furthermore, in step S1, the straightness error of the flat aluminum conductor after straightening is ≤0.5mm / m, the cleaning is performed by ultrasonic degreasing and oxide layer removal, the drying temperature is 80-100℃, and the drying time is 3-5 minutes.

[0015] Furthermore, in step S2, the flatness error of the flat aluminum conductor is ≤0.5mm.

[0016] Furthermore, in step S3, the extrusion temperature is 220~250℃, the traction speed is 3-5m / min, the cooling water temperature is 20-30℃, and the cooling time is 5-8 minutes.

[0017] Furthermore, in step S4, the extrusion temperature is 180-200℃, the traction speed is consistent with that in step S3, the thickness of the conductive resin shielding layer is 0.5mm, the cooling water temperature is 20-30℃, and the cooling time is 3-5 minutes.

[0018] Furthermore, in step S5, the spraying pressure is 0.3-0.5 MPa, the thickness of the graphene shielding reinforcement layer is 8-10 μm, the curing temperature is 120-150℃, and the curing time is 10-15 minutes.

[0019] Furthermore, in step S6, the extrusion temperature is 160-180℃, the traction speed is 3-5m / min, the thickness of the PVC outer insulation layer is 2.0mm, the cooling water temperature is 20-30℃, and the cooling time is 8-10 minutes.

[0020] Furthermore, in step S7, the cutting error is ≤ ±2mm, the bending radius is ≥ 5 times the thickness of the flat aluminum conductor, and the inspection items include but are not limited to appearance inspection, size inspection, shielding performance inspection, and high temperature resistance performance inspection.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. The high-voltage aluminum busbar produced by this process uses high-purity AL6101-T64 aluminum busbars with a large aspect ratio of 6.3mm thickness and 35mm width, which are stacked and combined to replace the traditional multi-strand stranded structure of round wire. Under the same cross-sectional area, the vertical space occupied is reduced, which can be adapted to the installation environment of tightly laid battery packs, motors and electronic control equipment in new energy vehicles, making the structure of the entire new energy vehicle and energy storage system battery pack product more compact.

[0023] 2. A high-temperature resistant nylon insulation layer is formed by continuous extrusion of high-temperature nylon using a 90-type extruder. After being cooled and fixed in a water tank, the insulation layer has a rated temperature of -40-125℃ and can withstand instantaneous heat up to 175℃ without significant damage. It has properties such as high elongation, anti-aging, flame retardancy, weather resistance, no cracking when bent, and scratch resistance. The conductive resin shielding layer is continuously extruded using a 90-type extruder and fixed by water tank cooling. Its rated temperature can reach -40-105℃ and can withstand instantaneous heat up to 155℃ without significant damage. It also has advantages such as high tensile strength, high elongation, anti-aging, heat resistance, and weather resistance. The PVC outer insulation layer is continuously extruded using a 120-type extruder and fixed by water tank cooling. Its rated temperature can also reach -40-105℃ and can withstand instantaneous heat up to 155℃ without significant damage. It is also flame retardant and scratch resistant, meeting the high-temperature working requirements of the charging assembly of new energy vehicles.

[0024] 3. A 0.5mm thick conductive resin shielding layer is continuously extruded outside the insulation layer using a 90-type extruder to form a complete, non-porous basic shielding structure. Then, an 8-10μm graphene shielding reinforcement layer is coated on its surface using a continuous spraying device and cured in an oven. The synergistic effect of the dual shielding structure can effectively block electromagnetic radiation, solving the problems of high porosity and discontinuous shielding in traditional round wire braided shielding, thereby improving anti-interference performance and ensuring the stable operation of electronic equipment in the vehicle.

[0025] 4. The outer insulation layer is made of PVC material and is continuously extruded by a 120-type extruder. The finished cable meets the ULVW-1 fire resistance rating, which can effectively improve the safety of the charging assembly of new energy vehicles and reduce the risk of fire.

[0026] 5. The conductor adopts a large aspect ratio AL6101-T64 aluminum busbar structure of 6.3mm×35mm. Compared with the traditional round wire multi-strand stranded conductor, it has a larger heat dissipation area and faster heat dissipation when carrying large currents. It can avoid performance degradation or safety hazards caused by heat accumulation and ensure the stable operation of high voltage aluminum busbar in high current transmission scenarios.

[0027] 6. On the one hand, by using aluminum conductors instead of traditional copper conductors and combining them with a flat, integrated structural design, material consumption is reduced and the cost of end materials is lowered. On the other hand, compared with the production process of traditional high-voltage power lines, this process has fewer production steps, avoiding resource waste caused by segmented processing. Attached Figure Description

[0028] Figure 1 This is a schematic flowchart of the production process of the novel shielded new energy vehicle charging assembly disclosed in an embodiment of the present invention;

[0029] Figure 2 This is a schematic cross-sectional view of the high-voltage aluminum busbar disclosed in an embodiment of the present invention.

[0030] In the diagram: 1. Flat aluminum conductor; 2. High-temperature resistant nylon insulation layer; 3. Conductive resin shielding layer; 4. Graphene shielding reinforcement layer; 5. PVC outer insulation layer. Detailed Implementation

[0031] 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.

[0032] Please see Figures 1-2 This invention provides a technical solution: a novel production process for high-voltage aluminum busbars used in shielded new energy vehicle charging assemblies. Through a continuous and automated production process, it achieves integrated composite molding of a flat aluminum conductor 1, a high-temperature resistant nylon insulation layer 2, a conductive resin shielding layer 3, a graphene shielding reinforcement layer 4, and a PVC outer insulation layer 5. The produced high-voltage aluminum busbar is suitable for high-current connections between the charging interface and the battery pack of new energy vehicles. The specific production operation process is as follows:

[0033] As an embodiment of the present invention, AL6101-T64 aluminum alloy ingots with qualified purity and stable performance are selected as raw materials. These ingots are then subjected to high-temperature extrusion processing using specialized extrusion equipment to form flat aluminum conductors 1 with a thickness of 6.3 mm and a width of 35 mm. To ensure the accuracy of subsequent layer coating, the formed flat aluminum conductors 1 need to be straightened. The straightness of the aluminum conductors is adjusted using straightening equipment to ensure that the straightness error is controlled within 0.5 mm / m after processing. Subsequently, the straightened aluminum conductors are sent to an ultrasonic cleaning device to remove surface oil, oxide layers, and other impurities using ultrasonic vibration. After cleaning, they are transferred to a hot air dryer for drying. The drying temperature is set at 80-100℃, and the drying time is maintained at 3-5 minutes to ensure that there are no residual water stains or impurities on the surface of the aluminum conductor, providing a good foundation for the tight bonding of subsequent insulation layers.

[0034] As an embodiment of the present invention, the conductor is further placed on a special positioning fixture, and the position of the conductor is fixed by the limiting effect of the fixture.

[0035] In one embodiment of the present invention, the positioned conductor assembly is fed uniformly into the feed inlet of a 90-type extruder. Simultaneously, high-temperature nylon raw material is added to the extruder barrel. The extruder's processing temperature is set to 220-250°C. After the raw material is fully melted and plasticized, the high-temperature nylon is evenly coated onto the outside of the conductor using an extrusion die. The coated aluminum busbar immediately enters a cooling water tank for shaping. The water temperature in the tank is controlled at 20-30°C. Rapid cooling with cold water solidifies the nylon insulation layer 2, maintaining a cooling time of 5-8 minutes to ensure a tight bond between the insulation layer and the conductor surface, free from defects such as bubbles, missing material, and wrinkles, ultimately forming a dense, high-temperature resistant nylon insulation layer 2.

[0036] In one embodiment of the present invention, the semi-finished aluminum busbar coated with the insulating layer is continuously fed into another 90-type extruder. The extruder's barrel is filled with thermoplastic conductive resin raw material, and the extrusion temperature is set to 180-200℃. The traction speed of the extruder is consistent with the previous insulating layer extrusion process to ensure uniform shielding layer thickness. After melting, the thermoplastic conductive resin is coated onto the outside of the high-temperature resistant nylon insulating layer 2 through a mold, forming a conductive resin shielding layer 3 with a thickness of 0.5mm. After coating, the aluminum busbar is again fed into a cooling water tank for cooling. The water temperature in the tank is maintained at 20-30℃, and the cooling time is 3-5 minutes, allowing the conductive resin shielding layer 3 to quickly solidify and form a strong bond with the insulating layer, ensuring the integrity and continuity of the shielding layer.

[0037] In one embodiment of the present invention, the aluminum busbar semi-finished product with conductive resin shielding layer 3 is further conveyed to a continuous electrostatic spraying equipment. The spraying equipment is loaded with graphene shielding coating material, and the spraying pressure is adjusted to 0.3-0.5 MPa, so that the coating material is uniformly adhered to the surface of the conductive resin shielding layer 3 under electrostatic action, forming a graphene shielding reinforcement layer 4 with a thickness of 8-10 μm. After spraying, the aluminum busbar is sent to a constant temperature oven for curing. The oven temperature is set to 120-150℃, and the curing time is controlled at 10-15 minutes. High-temperature curing ensures that the graphene shielding reinforcement layer 4 and the conductive resin shielding layer 3 are firmly bonded, filling any possible micropores in the shielding layer and improving the overall shielding effectiveness.

[0038] In one embodiment of the present invention, the cured aluminum busbar semi-finished product is further fed into a 120-type extruder. Flame-retardant PVC raw material is added to the extruder, the extrusion temperature is set to 160-180℃, and the traction speed is maintained at 3-5m / min. After the PVC raw material melts, it is evenly coated on the outside of the graphene shielding reinforcement layer 4 through the extrusion mold, forming a PVC outer insulation layer 5 with a thickness of 2.0mm. After the coating is completed, the aluminum busbar is sent into a cooling water tank for final cooling and shaping. The water temperature in the tank is 20-30℃, and the cooling time is 8-10 minutes, so that the PVC outer insulation layer 5 is fully cured, forming a protective structure with fireproof, wear-resistant, and corrosion-resistant functions. This completes the integrated composite molding of the various layers of the high-voltage aluminum busbar.

[0039] As an embodiment of the present invention, further, according to actual usage requirements, the continuously formed high-voltage aluminum busbar is cut to a specified length using a CNC shearing machine. During the cutting process, dimensional accuracy is strictly controlled to ensure a cutting error ≤ ±2mm. Subsequently, a dedicated peeling device is used to peel the aluminum busbar in layers, sequentially removing the PVC outer insulation layer 5, graphene shielding reinforcement layer 4, conductive resin shielding layer 3, and high-temperature resistant nylon insulation layer 2, exposing the flat aluminum conductor 1. According to bending parameters, the aluminum busbar is placed into a 3D CNC bending machine for bending and forming, with a bending radius not less than 5 times the thickness of the flat aluminum conductor 1 to avoid cracking or delamination at the bending point. Precision punching is performed on the exposed conductor ends to facilitate the subsequent installation and fixing of high-voltage connection terminals.

[0040] As an embodiment of the present invention, after processing, the finished high-voltage aluminum busbar is subjected to full-dimensional quality inspection, including appearance inspection, size inspection, shielding performance inspection, high temperature resistance performance inspection, etc. After all inspection items are qualified, the product is labeled, packaged, and finally put into the warehouse for shipment.

[0041] As an embodiment of the present invention, further, the appearance inspection includes, but is not limited to, checking whether each layer of the structure has cracks, delamination, peeling, or surface defects.

[0042] As an embodiment of the present invention, further, the size detection includes, but is not limited to, verifying conductor specifications, layer thickness, overall length, etc.

[0043] As an embodiment of the present invention, the shielding performance test further includes, but is not limited to, testing whether the electromagnetic shielding effectiveness meets the standard.

[0044] As an embodiment of the present invention, the high-temperature resistance test further includes, but is not limited to, verifying the stability of each layer of material under extreme temperatures.

[0045] It should be noted that all standard parts used in this application can be purchased from the market, and can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. The control method is automatic control through a control cabinet. The control circuit can be implemented by simple programming by those skilled in the art and is common knowledge in the field. Furthermore, since this application is mainly used to protect mechanical devices, this application will not explain the control method and circuit connection in detail.

Claims

1. A novel manufacturing process for high-voltage aluminum busbars used in shielded new energy vehicle charging assemblies, wherein the high-voltage aluminum busbars produced consist of, from the inside out, a flat aluminum conductor (1), a high-temperature resistant nylon insulation layer (2), a conductive resin shielding layer (3), a graphene shielding reinforcement layer (4), and a PVC outer insulation layer (5), characterized in that, Includes the following steps: S1. AL6101-T64 aluminum alloy ingots are extruded into flat aluminum conductors with a thickness of 6.3mm and a width of 35mm (1), which are then straightened, cleaned and dried. S2. Fix the flat aluminum conductor (1) using a positioning clamp; S3. High-temperature nylon is continuously extruded and coated on the outside of the flat aluminum conductor (1) using a 90-type extruder, and then cooled and shaped to form a high-temperature resistant nylon insulation layer (2). S4. A 90-type extruder is used to continuously extrude thermoplastic conductive resin onto the outside of the high-temperature resistant nylon insulation layer (2), and after cooling and shaping, a conductive resin shielding layer (3) is formed. S5. A graphene shielding reinforcement layer (4) is coated on the surface of the conductive resin shielding layer (3) by electrostatic spraying and then cured in an oven. S6. Flame-retardant PVC is continuously extruded and coated on the outside of the graphene shielding reinforcement layer (4) using a 120-type extruder, and then cooled and shaped to form a PVC outer insulation layer (5). S7. Cut the continuously formed high-pressure aluminum busbar, peel off the ends, bend it into shape, punch holes in the conductor, and package it into warehouse after passing the inspection.

2. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S1, the straightness error of the flat aluminum conductor (1) after straightening treatment is ≤0.5mm / m. The cleaning is performed by ultrasonic degreasing and deoxidation. The drying temperature is 80-100℃ and the drying time is 3-5 minutes.

3. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S2, the flatness error of the flat aluminum conductor (1) is ≤0.5mm.

4. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S3, the extrusion temperature is 220~250℃, the traction speed is 3-5m / min, the cooling water temperature is 20-30℃, and the cooling time is 5-8 minutes.

5. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S4, the extrusion temperature is 180-200℃, the traction speed is the same as in step S3, the thickness of the conductive resin shielding layer (3) is 0.5mm, the cooling water temperature is 20-30℃, and the cooling time is 3-5 minutes.

6. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S5, the spraying pressure is 0.3-0.5MPa, the thickness of the graphene shielding reinforcement layer (4) is 8-10μm, the curing temperature is 120-150℃, and the curing time is 10-15 minutes.

7. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S6, the extrusion temperature is 160-180℃, the traction speed is 3-5m / min, the thickness of the PVC outer insulation layer (5) is 2.0mm, the cooling water temperature is 20-30℃, and the cooling time is 8-10 minutes.

8. The manufacturing process for a novel shielded high-voltage aluminum busbar for a new energy vehicle charging assembly according to claim 1, characterized in that, In step S7, the cutting error is ≤ ±2mm, the bending radius is ≥ 5 times the thickness of the flat aluminum conductor (1), and the inspection items include but are not limited to appearance inspection, size inspection, shielding performance inspection, and high temperature resistance performance inspection.

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