Large-current flexible busbar cable

Abstract

The utility model discloses a large-current flexible busbar cable, which relates to the technical field of flexible busbar cables and comprises double-layer copper wire row conductors which are arranged in parallel, a polyimide film is wrapped outside the copper wire row conductors, a thermoplastic elastomer insulating layer is wrapped on the outer wall of the polyimide film, and a protective layer is wrapped on the outer wall of the thermoplastic elastomer insulating layer. The outer wall of the protective layer is wrapped with a corrugated sheath; according to the utility model, through layered flexible structure design, material performance optimization and process innovation, cooperative improvement of large-current transmission, high-frequency bending, high-efficiency heat dissipation and mechanical reliability is realized, and the problems of limited current-carrying capacity, easy fatigue fracture, high cost and the like of a traditional flexible busbar cable are solved; the application range of the large-current flexible busbar cable is further expanded, the cable production does not need a complex twisting process, the cable is suitable for batch production, and the utilization rate of raw materials is high.

Description

Technical Field

[0001] The utility model relates to the technical field of flexible busbar cables, in particular to a high-current flexible busbar cable. Background Art

[0002] Flexible busbar cable, also known as insulated soft busbar or laminated insulated soft busbar, is a power transmission element made by stacking multiple layers of corona-proof flat thin copper sheet conductors. The outside of the conductor is covered with an insulating layer by extrusion. It has many significant features and is widely used in many fields.

[0003] With the help of the flat conductor structure, the surface area is larger, the heat dissipation efficiency is higher, and it can carry more current. Under the same cross-sectional area, the current carrying capacity is increased by 10%-20% compared with the circular conductor. The patent "A Large-Section Flexible Mother Cable" increases the surface area of ​​the cable in contact with the air by making the cross-section of the mother cable flat, and also suppresses the skin effect of the current. However, the overall mechanical strength of the cable is low, and vibration or bending may cause single strands to break, reducing the overall reliability. External extrusion can easily deform the gaps between wires, affecting the current carrying capacity. At the same time, the gaps between wires may hinder heat dissipation in a closed environment, and heat conduction must rely on the external insulation layer, resulting in an increase in the overall manufacturing cost of the cable.

[0004] To this end, we propose a high-current flexible busbar cable. Utility Model Content

[0005] The utility model aims to provide a high-current flexible busbar cable to solve the problems raised in the background technology.

[0006] To achieve the above object, the utility model provides the following technical solution: a high-current flexible busbar cable, comprising a double-layer copper wire busbar conductor placed in parallel, the copper wire busbar conductor is wrapped with a polyimide film, the outer wall of the polyimide film is wrapped with a thermoplastic elastomer insulation layer, the outer wall of the thermoplastic elastomer insulation layer is wrapped with a protective layer, and the outer wall of the protective layer is wrapped with a corrugated sheath;

[0007] Grooves are provided on both sides of the copper wire conductor, the width and depth of the grooves are 0.7 mm, and the gap between adjacent grooves on the same side is 1.7 mm.

[0008] Furthermore, the protective layer comprises an ultra-thin aramid braided layer and an aluminum foil shielding layer, the thermoplastic elastomer insulating layer is wrapped with the aluminum foil shielding layer, and the outer wall of the aluminum foil shielding layer is wrapped with the ultra-thin aramid braided layer.

[0009] Furthermore, a foamed polyethylene buffer layer is filled in the gap between the polyimide film and the thermoplastic elastomer insulating layer.

[0010] Furthermore, the length of the copper wire conductor subjected to the softening annealing treatment is controlled within 38-42 mm, and the thickness is controlled within 2.8-3.2 mm.

[0011] Compared with the prior art, the beneficial effects of the utility model are:

[0012] In the utility model, through layered flexible structure design, material performance optimization and process innovation, the coordinated improvement of large current transmission, high-frequency bending, efficient heat dissipation and mechanical reliability is achieved, which solves the problems of limited current carrying capacity, easy fatigue fracture and high cost of traditional flexible busbar cables, and further broadens the scope of application of high-current flexible busbar cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic diagram of the overall structure of the high-current flexible busbar cable of the utility model;

[0014] Figure 2 This is a schematic diagram of the side cross-sectional structure of the high-current flexible busbar cable of the utility model;

[0015] Figure 3 This is a schematic diagram of the copper wire conductor structure of the utility model.

[0016] In the figure: 1. Copper wire conductor; 2. Polyimide film; 3. Foamed polyethylene buffer layer; 4. Thermoplastic elastomer insulation layer; 5. Protective layer; 501. Ultra-thin aramid braided layer; 502. Aluminum foil shielding layer; 6. Corrugated sheath. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0018] See also Figure 1-3 , the utility model provides a technical solution:

[0019] like Figure 1 The high-current flexible busbar cable shown in the figure uses T2 oxygen-free copper as the conductor. After softening annealing, the annealing temperature is 450±10℃ and the holding time is 30 minutes. After annealing, the hardness of the copper material is reduced to HV60-70, and the ductility is improved. At the same time, transverse grooves are processed on both sides of the conductor. The groove width is 0.7mm, the depth is 0.7mm, and the groove spacing is 1.7mm. Figure 3 As shown in the figure, due to the groove design, the entire conductor surface area is increased, and the appearance looks like a row structure of copper wires, so it is called a copper wire row conductor;

[0020] The outer side of the copper wire conductor is wrapped with a polyimide film as a wrapping layer with a thickness of 25μm. It is wrapped in two layers in a semi-overlapping manner with a wrapping angle of 45° and a temperature resistance level of ≥200℃ to provide initial insulation and mechanical protection. A foamed polyethylene buffer layer is also filled between the polyimide film and the thermoplastic elastomer insulation layer. The buffer layer is added between the wrapping layer and the insulation layer to absorb mechanical stress and reduce the pressure on the conductor during bending. The foaming rate of the foamed polyethylene buffer layer is 70%, the density is controlled at 0.12g / cm³, and the thickness is 0 .5mm, it is bonded to the film through a hot pressing process to absorb bending stress, reduce the risk of conductor deformation under pressure, and improve the heat dissipation effect. For example, the invention patent "A composite cable material with thermal conductivity and insulation enhanced by adding modified boron nitride silicone rubber" is similar. Boron nitride after coupling modification is added to methyl vinyl silicone rubber through internal mixing and open mixing to make filler and add it to the matrix low-density polyethylene. It can be evenly dispersed with the matrix, has good interface compatibility, and improves the thermal conductivity of the material. Therefore, boron nitride powder is also added to the foamed polyethylene buffer layer;

[0021] At the same time, the protective layer is installed on the insulation layer and the sheath layer. The protective layer here is mainly non-metallic armor. In the high-current flexible busbar cable, a non-metallic armor layer is added to enhance the mechanical protection capability while taking into account the flexibility requirements. At the same time, the non-metallic armor is lighter and more flexible than the traditional metal armor, and does not introduce eddy current loss. It is especially suitable for scenes that require frequent bending or are sensitive to electromagnetic interference;

[0022] The non-metallic armor here uses an ultra-thin aramid braided layer with a braiding density of 80 meshes, a thickness of 0.3mm, and a tensile strength of ≥3000N / cm². It is covered on the outside of the aluminum foil shielding layer to improve the tear and impact resistance. At the same time, an aluminum foil shielding layer is installed on the inside of the ultra-thin aramid braided layer. It is 0.05mm aluminum foil with a 30% overlap rate. After wrapping, it is covered with conductive glue, and the shielding efficiency is ≥90dB;

[0023] As for the thermoplastic elastomer insulation layer, it is a styrene thermoplastic elastomer, extruded, with a thickness of 1.2mm and an extrusion temperature of 180-200°C, ensuring seamless fit with the buffer layer;

[0024] The outermost sheath layer is made of thermoplastic polyurethane, and the surface is corrugated with a corrugation depth of 2mm, a wave distance of 4mm, and an outer diameter of 8mm. It is bonded to the protective layer through an injection molding process, allowing axial expansion and contraction and free deformation within a larger bending radius.

[0025] Through the above structural innovation, the high-current flexible busbar cable can achieve an optimized balance between high-current carrying capacity and flexibility, and is suitable for high-frequency bending, vibration or narrow space installation scenarios, while supporting multi-conductor stacking design, such as Figure 2As shown, only two-row conductors are assembled, and three-row, four-row and multi-row structure designs can be performed later to reduce wiring complexity and improve system integration.

[0026] The above contents are merely examples and explanations of the structure of the utility model. The technicians in this technical field may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the structure of the utility model or exceed the scope defined in the claims, they should all fall within the protection scope of the utility model.

[0027] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. 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.

[0028] The preferred embodiments of the utility model disclosed above are only used to help explain the utility model. The preferred embodiments do not describe all the details in detail, nor do they limit the utility model to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the utility model, so that technicians in the relevant technical field can well understand and use the utility model. The utility model is only limited by the claims and their full scope and equivalents.

Claims

1. A high current flexible busbar cable, characterized by: It comprises a double-layer copper wire conductor (1) placed in parallel, the copper wire conductor (1) is wrapped with a polyimide film (2) on the outside, the outer wall of the polyimide film (2) is wrapped with a thermoplastic elastomer insulation layer (4), the outer wall of the thermoplastic elastomer insulation layer (4) is wrapped with a protective layer (5), and the outer wall of the protective layer (5) is wrapped with a corrugated sheath (6); The copper wire conductor (1) is provided with grooves on both sides, the groove width and depth are 0.7 mm, and the gap between adjacent grooves on the same side is 1.7 mm.

2. A high current flexible busbar cable according to claim 1, characterized in that: The protective layer (5) comprises an ultra-thin aramid braided layer (501) and an aluminum foil shielding layer (502); the thermoplastic elastomer insulating layer (4) is wrapped with the aluminum foil shielding layer (502); and the outer wall of the aluminum foil shielding layer (502) is wrapped with the ultra-thin aramid braided layer (501).

3. A high current flexible busbar cable according to claim 2, characterized in that: The gap between the polyimide film (2) and the thermoplastic elastomer insulating layer (4) is filled with a foamed polyethylene buffer layer (3).

4. A high current flexible busbar cable according to claim 3, characterized in that: The copper wire conductor (1) subjected to the softening annealing treatment has a length of 38-42 mm and a thickness of 2.8-3.2 mm.

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