High-flexibility tinned braided copper bar bus

Abstract

The utility model discloses a high-flexibility tin-plated braided copper bar bus which comprises a tin-plated braided copper bar layer, a wrapping layer and an outer sheath layer. The wrapping layer wraps the outer layer of the tinned braided copper bar in a radial wrapping mode, and the outer sheath layer wraps the outer layer of the wrapping layer in an extruding or wrapping mode. According to the high-flexibility tinned braided copper bar bus, after the high-purity copper bars are tinned, the high-flexibility tinned braided copper bar bus has good conductivity, the bus manufactured by the high-flexibility tinned braided copper bar bus has good flexibility, the tinned bus is stable in oxidation resistance, and a solid foundation is provided for application of the high-flexibility tinned braided copper bar bus in places with high flexibility requirements in the electrical and electronic fields.

Description

Technical Field

[0001] The utility model relates to the technical field of copper busbars, in particular to a high-flexibility tin-plated braided copper busbar. Background Art

[0002] The high performance requirements of power systems and electronic devices have driven the continuous development of busbar technology. Highly flexible busbars are particularly important in some special application areas, such as electric vehicles, wearable devices, and flexible electronics. Traditional copper busbars are limited in these applications due to their rigidity and weight. Utility Model Content

[0003] The utility model aims to solve at least one of the technical problems existing in the prior art. To this end, an embodiment of the utility model proposes a high-flexibility tinned braided copper busbar. The high-flexibility tinned braided copper busbar proposed in the embodiment of the utility model includes: a tinned braided copper busbar layer, a wrapping layer, and an outer sheath layer; the wrapping layer is radially wrapped around the outer layer of the tinned braided copper busbar, and the outer sheath layer is extruded or wrapped around the outer layer of the wrapping layer.

[0004] Furthermore, the tinned braided copper busbar layer is at least two layers.

[0005] Furthermore, the wrapping layer is a single-layer wrapping or a double-layer wrapping.

[0006] Furthermore, the wrapping layer is made of polyester tape or mica tape.

[0007] Furthermore, the outer sheath layer is made of polyvinyl chloride material or flame-retardant polyvinyl chloride material.

[0008] Furthermore, the outer sheath layer has a minimum thickness of 0.1 mm.

[0009] Furthermore, it also includes an armor layer, which is interlocked with the outer layer of the outer sheath layer.

[0010] Furthermore, the thickness of the armor layer is 1.5 mm.

[0011] The highly flexible tin-plated braided copper busbar proposed in the embodiment of the utility model has good electrical conductivity after tinning using high-purity copper busbars. The busbars produced by the tinning method have good flexibility, and the oxidation resistance of the busbars is stable after tinning, which provides a solid foundation for their application in places requiring higher flexibility in the electrical and electronic fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0013] Figure 1 Schematic diagram of high-flexibility tinned braided copper busbar;

[0014] Figure 2 AA section side view of highly flexible tinned braided copper busbar;

[0015] Figure 3 Schematic diagram of high-flexibility tinned braided copper busbar weaving;

[0016] Reference numerals:

[0017] Tinned braided copper busbar 1, sheath layer 2, outer sheath layer 3, insulation layer 4, armor layer 5. DETAILED DESCRIPTION

[0018] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0019] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., and orientations or positional relationships indicated are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0020] In the description of the present invention, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0021] The high performance requirements of power systems and electronic devices have driven the continuous development of busbar technology. Highly flexible busbars have become particularly important in some special applications such as electric vehicles, wearable devices, and flexible electronics. Traditional copper busbars are limited in these applications due to their rigidity and weight. To overcome these problems, we proposed a new type of highly flexible tinned braided copper busbar.

[0022] Reference Figure 1 and Figure 2 As shown, a novel high-flexibility tinned braided copper busbar proposed in this embodiment comprises: a tinned high-purity braided copper wire layer 1, a wrapping layer 2, an insulating layer 3, and an outer sheath layer 4;

[0023] The busbar conductor uses high-purity copper as the base material, which has excellent electrical conductivity and mechanical strength. The choice of high-purity copper is to ensure that the busbar performs well in current conduction while maintaining good mechanical stability. By using advanced weaving technology, a detailed and uniform weaving structure is accurately constructed, providing excellent flexibility and plasticity, allowing the busbar to adapt to a variety of complex layouts and changing shapes.

[0024] Reference Figure 3 As shown, the high-purity copper wire can be selected with a specification of 0.2-2.5mm copper wire, which is woven in a cross manner or a cross manner. After the copper bar is woven and the copper braiding structure is completed, the surface of the copper bar is tinned. The tinning thickness is 0.2-0.5mm, and the braiding width can be from 20mm-800mm.

[0025] After the braided copper busbar is tinned, it is wrapped on its outer layer, using a single layer or two layers of overlapping wrapping. The wrapping tape is made of polyester tape, mica tape and other materials required in specific environments. The wrapping direction is wrapped along the radial direction of the busbar copper busbar, with an overlapping width of 10-20%, and a wrapping thickness of not less than 0.2mm; the copper busbar has a flat surface after wrapping; the wrapping tape is tightly wrapped on the surface of the copper busbar. When two layers of overlapping wrapping are used, the wrapping directions of the first layer and the second layer should be opposite.

[0026] Then, the wrapping layer is insulated to form an insulating layer 4. The insulating layer adopts a 105° polyvinyl chloride mixture W" specification. The W specification material is an outdoor waterproof wire material that meets the outdoor waterproof usage scenario. For example, the following materials can be used:

[0027] 1. Insulation resistance at 15℃: waterproof material requirement is ≥69, and ordinary indoor use requirement is ≥0.76.

[0028] 2. The outdoor temperature is relatively low, reaching -40℃ cold resistance level. The ordinary indoor temperature requires -15~20℃. The insulation should be tightly packed on the conductor, and the insulation surface should be flat and uniform in color. The thickness of the insulation should not be less than the specified value in this table, and the thickness of the thinnest point should not be less than 90% of the specified value-0.1mm.

[0029] In order to further improve the wear resistance and flame retardancy of the busbar, an outer sheath layer is made on the outer layer of the insulation layer. The outer sheath layer is made of polyvinyl chloride material or flame retardant polyvinyl chloride material, and the outer sheath color is black and orange. The nominal thickness of the extruded outer sheath should be as follows: t = 0.035D + 1.0mm, where D is the thickness of the high-flexible tinned copper busbar bus conductor after insulation, and the minimum sheath thickness should not be less than 80% of the specified value minus 0.2mm.

[0030] According to the usage scenario, metal can also be used in the outer sheath layer for interlocking armor to form an armor layer 5. The metal material used for the armor can be a non-magnetic alloy material. The thickness of the outer sheath after armoring is 0.8-2.5mm.

[0031] A preparation process of a braided copper busbar is also proposed for the tinned copper busbar of this embodiment, and the preparation process is as follows:

[0032] Step 1: Clean and surface treat the high-purity copper wire to remove possible oxides and impurities to ensure the purity of the braided structure. Use a high-precision braiding machine to weave the copper wire into a flexible braided structure. Adjust the braiding machine parameters, such as weaving density and weaving method, to obtain the required flexibility and conductivity. The weaving method can be cross braiding or cross winding braiding, and the copper is arranged in a rectangular shape after weaving.

[0033] Step 2: In order to enhance the corrosion resistance and stability of the busbar, after the copper braided structure is completed, the copper busbar surface is tinned. This step uses electrochemical deposition technology to ensure that tin is evenly attached to the copper surface to form a dense and solid protective layer. Then the tinned braided copper busbar is properly heat treated, and the braided copper busbar is placed in a heat treatment furnace at an appropriate temperature. The temperature is controlled within a suitable range to ensure that the braided copper busbar is kept in the heat treatment furnace for a sufficient time to achieve the adjustment of the crystal structure and the improvement of performance. After the heat treatment is completed, the braided copper busbar is gradually cooled to room temperature to ensure its structure and performance stability. Tin plating not only effectively improves the corrosion resistance of the busbar, but also provides additional mechanical support and enhances the durability of the busbar. This composite structure not only makes the busbar superior in electrical performance, but also has good environmental adaptability and is suitable for a wide range of applications.

[0034] The braided tinned copper busbar produced by the above preparation process was subjected to a series of multi-faceted performance tests in order to comprehensively evaluate the performance of the highly flexible tinned braided copper busbar. These tests covered multiple key aspects such as conductivity, flexibility, and stability to ensure the reliability of the busbar in various practical applications.

[0035] The excellent performance of tinned braided copper busbars has been verified through a series of rigorous conductivity tests. The test results clearly show that compared with traditional copper busbars, tinned braided copper busbars have achieved significant improvements in conductivity. Its low resistance characteristics indicate that the busbar can conduct current more effectively, reduce power loss, and provide reliable support for the efficient operation of the electrical system.

[0036] In the bending and stretching tests, the tinned braided copper busbar showed excellent flexibility and deformation ability. Under the conditions of multiple bending and stretching, the busbar maintained its original shape without breaking or performance degradation. This shows that the braided copper busbar not only performs well under stable working conditions, but also has excellent adaptability in application scenarios with complex shapes and curved arrangements. This flexibility allows the busbar to easily adapt to various space constraints and design requirements.

[0037] The stability of the busbar under temperature changes was evaluated through thermal cycle testing. Cycles under different temperature conditions were simulated to verify the performance retention of the highly flexible tinned braided copper busbar under temperature changes. The test results showed that the busbar performed well under thermal cycle conditions, with excellent stability and temperature resistance, providing reliable electrical connections for various complex working environments.

[0038] In summary, the highly flexible tinned braided copper busbar has brought extensive and eye-catching application prospects to electric vehicles, flexible electronics, wearable devices and other fields with its excellent performance. In the field of electric vehicles, the high conductivity and excellent flexibility of the busbar make it an ideal choice for battery systems, motor drives and power distribution. Its superior conductivity can effectively reduce current transmission losses and improve the efficiency of batteries and motors, thereby extending the range of electric vehicles. In the field of flexible electronics and wearable devices, the highly flexible braided copper busbar can easily adapt to the curves and shapes of the equipment, providing greater freedom in the design of flexible electronic products. The use of this busbar can improve the stability and durability of the equipment, while providing reliable electrical connections for lighter and more comfortable wearable devices. Its flexible design also makes the busbar more comfortable in wearable devices, providing users with a better experience. The wide application of busbars will not be limited to the above fields.

[0039] In the continuous innovation of electronic equipment, highly flexible tinned braided copper busbars will become an important component, providing support for the development of various emerging technologies and products. Its application prospects in multiple fields will promote the innovative development of power systems and electronic equipment, and drive the entire industry towards a more efficient and reliable future. The introduction of this busbar will inject new vitality into modern electrical and electronic systems, promote technological progress, and achieve more sustainable energy utilization and intelligent electronic products.

[0040] The above is only a preferred embodiment of the present utility model. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present utility model. These improvements and modifications should also be regarded as protection of the present utility model.

[0041] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0042] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A highly flexible tinned braided copper busbar, characterized in that: include: A tinned braided copper busbar layer, a wrapping layer and an outer sheath layer; the wrapping layer is radially wrapped around the outer layer of the tinned braided copper busbar, and the outer sheath layer is extruded or wrapped around the outer layer of the wrapping layer.

2. The highly flexible tinned braided copper busbar according to claim 1, characterized in that: The tinned braided copper busbar layer is at least two layers.

3. The highly flexible tinned braided copper busbar according to claim 1, characterized in that: The wrapping layer is a single-layer wrapping or a double-layer wrapping.

4. The highly flexible tinned braided copper busbar according to claim 3, characterized in that: The wrapping layer is made of polyester tape or mica tape.

5. The highly flexible tinned braided copper busbar according to claim 1, characterized in that: The outer sheath layer is made of polyvinyl chloride material or flame-retardant polyvinyl chloride material.

6. The highly flexible tinned braided copper busbar according to claim 5, characterized in that: The outer sheath layer has a minimum thickness of 0.1 mm.

7. The highly flexible tinned braided copper busbar according to claim 1, characterized in that: Also included is an armor layer interlocked with the outer jacket layer.

8. The highly flexible tinned braided copper busbar according to claim 7, characterized in that: The thickness of the armor layer is 1.5 mm.

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