Fireproof injection molding busbar

Abstract

The utility model provides a fireproof injection molding busbar which comprises a conductor layer, a support clip assembly and a fireproof insulation layer. Supporting clip assembly holes are formed in the conductor layer main body at intervals along the length direction; each supporting clip assembly is assembled and mounted in the corresponding supporting clip assembly hole; and the fire-resistant insulating layer is coated outside the conductor layer main body and the support clip assembly in an injection molding manner. According to the fire-resistant injection molding busbar provided by the utility model, firstly, the conductor is formed by stamping, bending and other processes, then the supporting clip is assembled at a specified position of the conductor, and finally, the fire-resistant injection molding busbar with good fire resistance and insulativity is obtained through injection molding, so that the safety performance of the busbar and a battery pack is greatly improved, and the service life of the busbar is prolonged. A powerful guarantee is provided for the safety of the whole vehicle; and the production process is simple, the processing precision is easy to control, multi-dimensional forming can be realized, the structure is reasonable and compact, and the appearance is attractive and elegant.

Description

Technical Field

[0001] The utility model relates to a busbar structure, in particular to a fire-resistant injection-molded busbar. Background Art

[0002] With the rapid growth of new energy vehicle ownership, related safety accidents have also gradually increased, becoming the focus of consumer attention. In new energy vehicles, the busbar structure used in the power battery pack is a conventional busbar structure, which is not fire-resistant and is one of the factors that lead to fires in new energy vehicle cells. Therefore, how to design a busbar structure to improve its fire resistance is a key issue that needs to be solved at present. Utility Model Content

[0003] In view of the defects in the prior art, the utility model provides a fire-resistant injection-molded busbar, which can effectively solve the above problems.

[0004] The technical solution adopted by the utility model is as follows:

[0005] The utility model provides a fire-resistant injection-molded busbar, comprising a conductor layer (1), a support clip assembly (2) and a fire-resistant insulating layer (3);

[0006] The conductor layer (1) comprises a conductor layer body (1-1) and end caps (1-2) located at both ends of the conductor layer body (1-1); support clip assembly holes (1-3) are provided on the conductor layer body (1-1) at intervals along the length direction; each of the support clip assembly holes (1-3) is assembled and installed with the support clip assembly (2); the upper end surface of the support clip assembly (2) is higher than the upper surface of the conductor layer body (1-1), the lower end surface of the support clip assembly (2) is higher than the lower surface of the conductor layer body (1-1), and the side surface of the support clip assembly (2) is higher than the side surface of the conductor layer body (1-1), and the height of the side surface of the support clip assembly (2) is the same; the fire-resistant insulating layer (3) is injection-molded on the outside of the conductor layer body (1-1) and the support clip assembly (2), and the outer surface of the fire-resistant insulating layer (3) is flush with the corresponding outer surface of the support clip assembly (2).

[0007] Preferably, the end head (1-2) is provided with an assembly hole.

[0008] Preferably, the conductor layer (1) is a copper plate, a hard aluminum plate, a multi-layer copper strip or a multi-layer aluminum strip, with a thickness of ≥1.5 mm.

[0009] Preferably, the support clip assembly (2) and the fire-resistant insulation layer (3) are made of the same material, which is thermoplastic material.

[0010] Preferably, the support clip assembly (2) comprises a first horizontal plate (2-1), a second horizontal plate (2-2) and a vertical plate (2-3); the first horizontal plate (2-1) and the second horizontal plate (2-2) are respectively clamped on the upper surface and the lower surface of the conductor layer body (1-1); the ends of the first horizontal plate (2-1) and the second horizontal plate (2-2) are connected by the vertical plate (2-3); the vertical plate (2-3) is clamped on the side of the conductor layer body (1-1);

[0011] The first horizontal plate (2-1) and the second horizontal plate (2-2) are provided with through holes which are connected with the support clip assembly hole (1-3); bolts pass through the through holes and the support clip assembly hole (1-3), and first nuts (2-4) are respectively assembled at both ends of the bolts; and a second nut (2-5) is assembled at the outer center of the vertical plate (2-3).

[0012] Preferably, the supporting clip components (2) are arranged at intervals on the front and rear sides of the conductor layer body (1-1).

[0013] Preferably, the distance between two adjacent support clip assemblies (2) is 100 mm.

[0014] Preferably, the thickness of the fire-resistant insulating layer (3) is 1.5-2.5 mm.

[0015] The utility model provides a fire-resistant injection molded busbar with the following advantages:

[0016] The utility model provides a fire-resistant injection-molded busbar. First, the conductor is formed by processes such as stamping and bending, and then the support clips are assembled to the specified positions of the conductors. Finally, by injection molding, a fire-resistant injection-molded busbar with good fire resistance and insulation is obtained, which greatly improves the safety performance of the busbar and the battery pack, and provides a strong guarantee for the safety of the whole vehicle. It also has the advantages of simple production process, easy control of processing accuracy, multi-dimensional molding, reasonable and compact structure, and beautiful appearance. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 A cross-sectional schematic diagram of the fire-resistant injection-molded busbar provided by the utility model at the installation position of the support clip assembly;

[0018] Figure 2 An assembly diagram of the conductor layer and the support clip assembly provided by the utility model;

[0019] Figure 3 A three-dimensional diagram of the fire-resistant injection-molded busbar provided by the utility model;

[0020] Figure 4 A front view of the fire-resistant injection-molded busbar provided by the utility model;

[0021] Figure 5 An exploded view of the fire-resistant injection-molded busbar provided by the utility model. DETAILED DESCRIPTION

[0022] In order to make the technical problems, technical solutions and beneficial effects solved by the utility model more clear, the utility model is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the utility model and are not used to limit the utility model.

[0023] The utility model provides a fire-resistant injection-molded busbar. First, the conductor is formed by processes such as stamping and bending, and then the support clips are assembled to the specified positions of the conductors. Finally, by injection molding, a fire-resistant injection-molded busbar with good fire resistance and insulation is obtained, which greatly improves the safety performance of the busbar and the battery pack, and provides a strong guarantee for the safety of the whole vehicle. It also has the advantages of simple production process, easy control of processing accuracy, multi-dimensional molding, reasonable and compact structure, and beautiful appearance.

[0024] See also Figures 1 to 5 , the utility model provides a fire-resistant injection-molded busbar, comprising a conductor layer 1, a support clip assembly 2 and a fire-resistant insulation layer 3;

[0025] The conductor layer 1 has a conductor layer body 1-1 and terminals 1-2 located at both ends of the conductor layer body 1-1; the terminals 1-2 are provided with assembly holes, which are used to realize electrical connection between the conductor layer 1 and other conductive parts. The conductor layer 1 can be a copper plate, a hard aluminum plate, a multi-layer copper strip or a multi-layer aluminum strip, with a thickness of ≥1.5 mm.

[0026] like Figure 5 As shown, on the conductor layer body 1-1, support clip assembly holes 1-3 are arranged at intervals along the length direction; each support clip assembly hole 1-3 is assembled and installed with a support clip assembly 2; wherein, the upper end surface of the support clip assembly 2 is higher than the upper surface of the conductor layer body 1-1, the lower end surface of the support clip assembly 2 is higher than the lower surface of the conductor layer body 1-1, and the side surface of the support clip assembly 2 is higher than the side surface of the conductor layer body 1-1, and the heights are the same;

[0027] As a specific example of a support clip assembly 2, the support clip assembly 2 is a thermoplastic material. The support clip assembly 2 includes a first horizontal plate 2-1, a second horizontal plate 2-2 and a vertical plate 2-3; the thickness of the first horizontal plate 2-1, the second horizontal plate 2-2 and the vertical plate 2-3 is 1±0.1 mm; the first horizontal plate 2-1 and the second horizontal plate 2-2 are respectively clamped on the upper surface and the lower surface of the conductor layer body 1-1; the ends of the first horizontal plate 2-1 and the second horizontal plate 2-2 are connected by the vertical plate 2-3; the vertical plate 2-3 is clamped on the side of the conductor layer body 1-1;

[0028] The first horizontal plate 2-1 and the second horizontal plate 2-2 are provided with through holes that are connected to the support clip assembly hole 1-3; the bolt passes through the through hole and the support clip assembly hole 1-3, and the first nut 2-4 is respectively assembled at both ends of the bolt; the second nut 2-5 is assembled at the outer center of the vertical plate 2-3. By controlling the size of the support clip assembly 2, the first nut 2-4 and the second nut 2-5 have the same thickness, and the first horizontal plate 2-1, the second horizontal plate 2-2 and the vertical plate 2-3 have the same thickness. After the first nut 2-4 and the second nut 2-5 are assembled, the first nut 2-4 is closely attached to the surface of the first horizontal plate 2-1 or the second horizontal plate 2-2, and the second nut 2-5 is closely attached to the surface of the vertical plate 2-3, so that the distance between the top surface of the first nut 2-4 and the first horizontal plate 2-1 or the second horizontal plate 2-2 is equal to the distance between the top surface of the second nut 2-5 and the vertical plate 2-3. Therefore, when the fire-resistant insulating layer 3 is subsequently injection-molded and coated, the surfaces of the first nut 2-4 and the second nut 2-5 are used as height standards, so that the surface of the fire-resistant insulating layer 3 after injection molding is equal to the surface of the first nut 2-4 and the second nut 2-5, thereby ensuring the uniformity of the wall thickness of the fire-resistant insulating layer 3.

[0029] Since the fire-resistant insulating layer 3 needs to be injection molded on the upper and lower surfaces and the outside of the front and rear sides of the conductor layer body 1-1, in order to ensure the uniformity of the injection wall thickness of the four surfaces, the support clip assemblies 2 are arranged at intervals on the front and rear sides of the conductor layer body 1-1. As an embodiment, the distance between two adjacent support clip assemblies 2 is 100 mm. Therefore, by assembling the support clip assemblies 2, the present application can simply and conveniently achieve the uniformity of the wall thickness of each injection molding of the fire-resistant insulating layer and ensure the injection molding quality.

[0030] The fire-resistant insulating layer 3 is injection-molded and coated on the outside of the conductor layer body 1-1 and the support clip assembly 2, and the outer surface of the fire-resistant insulating layer 3 is flush with the corresponding outer surface of the support clip assembly 2. The material of the fire-resistant insulating layer 3 can be a thermoplastic material. The thickness of the fire-resistant insulating layer 3 can be 1.5-2.5 mm.

[0031] An embodiment is described below:

[0032] A fire-resistant injection-molded busbar provided in this embodiment is a fire-resistant extruded hard busbar structure, comprising a conductor layer 1, a support clip assembly 2 and a fire-resistant insulation layer 3; the conductor layer 1 is formed by processes such as stamping and bending, and the conductor layer 1 has support clip assembly holes 1-3, which are reserved hole positions, and the support clip assembly 2 is assembled to the reserved hole positions of the conductor layer 1; the fire-resistant insulation layer 3 is coated on the surface of the conductor layer 1 and the support clip assembly 2 through an injection molding process to form a fire-resistant injection-molded busbar.

[0033] The conductor layer 1 adopts a copper plate structure with a copper plate thickness of ≥1.5 mm. The conductor can also be a hard aluminum plate, a multi-layer copper strip or a multi-layer aluminum strip, which has excellent conductive properties.

[0034] The fire-resistant insulating layer 3 is a thermoplastic material, which is mainly composed of TPU, EVA, POP and the like, and has excellent insulation, fire-resistant, flame-retardant, aging-resistant, impact-resistant, wear-resistant and other properties; the thickness of the fire-resistant insulating layer 3 is 1.5-2.5 mm, which can ensure excellent insulation, wear-resistant, fire-resistant and other performance effects;

[0035] The support clip assembly 2 is made of the same material as the fire-resistant insulation layer 3. The function of the support clip assembly 2 is to support the copper busbar to prevent uneven wall thickness of the fire-resistant insulation layer 3 during the injection molding process. The support clip assembly 2 is evenly arranged in the length direction of the conductor layer 1. The distance between the two support clip assemblies 2 is 100mm, that is, the support clip assembly 2 needs to be set when the length of the busbar in a certain direction is ≥100mm. When the length of the busbar in all directions is <100mm, the support clip assembly 2 does not need to be set. When the conductor layer 1 is stamped, a hole with a diameter of 5mm needs to be punched out at the position where the support clip assembly 2 is to be assembled to prevent the support clip assembly 2 from moving and causing the injection molded busbar size to be out of tolerance, which meets the design requirements and does not affect the performance.

[0036] The utility model provides a fire-resistant injection-molded busbar. First, the conductor is formed by processes such as stamping and bending, and then the support clips are assembled to the specified positions of the conductors. Finally, by injection molding, a fire-resistant injection-molded busbar with good fire resistance and insulation is obtained, which greatly improves the safety performance of the busbar and the battery pack, and provides a strong guarantee for the safety of the whole vehicle. It also has the advantages of simple production process, easy control of processing accuracy, multi-dimensional molding, reasonable and compact structure, and beautiful appearance.

[0037] The above is only a preferred embodiment of the present invention. It should be pointed out that ordinary technicians in this technical field can make several improvements and modifications without departing from the principle of the present invention. These improvements and modifications should also be considered as the protection scope of the present invention.

Claims

1. A refractory injection molded busbar, characterized in that: It comprises a conductor layer (1), a support clip assembly (2) and a fire-resistant insulating layer (3); The conductor layer (1) comprises a conductor layer body (1-1) and end caps (1-2) located at both ends of the conductor layer body (1-1); support clip assembly holes (1-3) are provided on the conductor layer body (1-1) at intervals along the length direction; each of the support clip assembly holes (1-3) is assembled and installed with the support clip assembly (2); the upper end surface of the support clip assembly (2) is higher than the upper surface of the conductor layer body (1-1), the lower end surface of the support clip assembly (2) is higher than the lower surface of the conductor layer body (1-1), and the side surface of the support clip assembly (2) is higher than the side surface of the conductor layer body (1-1), and the height of the side surface of the support clip assembly (2) is the same; the fire-resistant insulating layer (3) is injection-molded on the outside of the conductor layer body (1-1) and the support clip assembly (2), and the outer surface of the fire-resistant insulating layer (3) is flush with the corresponding outer surface of the support clip assembly (2).

2. A refractory injection molded busbar according to claim 1, characterized in that: The end head (1-2) is provided with an assembly hole.

3. A refractory injection molded busbar according to claim 1, characterized in that: The conductor layer (1) is a copper plate, a hard aluminum plate, a multi-layer copper strip or a multi-layer aluminum strip, and has a thickness of ≥1.5 mm.

4. A refractory injection molded busbar according to claim 1, characterized in that: The supporting clip assembly (2) and the fire-resistant insulation layer (3) are made of the same material, which is thermoplastic material.

5. The refractory injection molded busbar according to claim 1, characterized in that: The support clip assembly (2) comprises a first horizontal plate (2-1), a second horizontal plate (2-2) and a vertical plate (2-3); the first horizontal plate (2-1) and the second horizontal plate (2-2) are respectively clamped on the upper surface and the lower surface of the conductor layer body (1-1); the ends of the first horizontal plate (2-1) and the second horizontal plate (2-2) are connected through the vertical plate (2-3); the vertical plate (2-3) is clamped on the side of the conductor layer body (1-1); The first horizontal plate (2-1) and the second horizontal plate (2-2) are provided with through holes which are connected with the support clip assembly hole (1-3); bolts pass through the through holes and the support clip assembly hole (1-3), and first nuts (2-4) are respectively assembled at both ends of the bolts; and a second nut (2-5) is assembled at the outer center of the vertical plate (2-3).

6. A refractory injection molded busbar according to claim 1, characterized in that: The supporting clip components (2) are arranged at intervals on the front and rear sides of the conductor layer body (1-1).

7. The refractory injection molded busbar according to claim 1, characterized in that: The distance between two adjacent support clip assemblies (2) is 100 mm.

8. The refractory injection molded busbar according to claim 1, characterized in that: The thickness of the fire-resistant insulating layer (3) is 1.5-2.5 mm.

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