Copper bar conductive connecting piece structure of new energy automobile

Abstract

The utility model discloses a new energy automobile copper bar conductive connecting sheet structure, which comprises a metal connecting sheet and an insulating material piece, the insulating material piece comprises an adhesive layer, a mica layer and a PI layer, the adhesive layer, the mica layer and the PI layer are sequentially laminated from bottom to top, the PI layer covers the outer side of the mica layer, and the PI layer covers the outer side of the mica layer. And the mica layer is attached to the outer wall of the metal connecting sheet through the adhesive layer. According to the insulating material piece, the adhesive layer, the mica layer and the PI layer are combined into a whole in a stacked mode, the breakthrough of winding and wrapping the metal connecting piece at a time is achieved, the wrapping efficiency is improved, connection gaps prone to occurring in traditional layer-by-layer winding are avoided, and therefore the continuity and integrity of the insulating material are guaranteed, and the service life of the insulating material piece is prolonged. And the insulation performance and the reliability of the product are obviously improved. And the integrated laminating and coating technology is more economical in material use, repeated coating is reduced, material waste is avoided, cost is reduced, direct material cost is saved for enterprises, and more energy-saving and environment-friendly effects are achieved.

Description

Technical Field

[0001] This utility model relates to the technology of power supply in new energy vehicles, and in particular to a copper busbar conductive connection piece structure for new energy vehicles. Background Technology

[0002] In the field of new energy vehicles, copper busbar conductive connectors are key components for ensuring the stable operation of battery systems. However, traditional copper busbar conductive connectors are wound with insulation layers using a layer-by-layer winding method. This method is prone to creating gaps at the junctions between layers, leading to a decrease in insulation performance and posing safety hazards.

[0003] To ensure insulation at the joints, these areas often need to be repeatedly wound, which not only increases material costs but also reduces production efficiency. Furthermore, this manual winding method is difficult to adapt to the demands of automated production, limiting the efficiency and cost control of large-scale manufacturing.

[0004] Therefore, it is necessary to develop a new copper busbar conductive connector and its insulating winding method to improve insulation performance, reduce material waste, and increase production efficiency, so as to meet the new energy vehicle industry's continuous pursuit of high performance, high reliability, and cost-effectiveness. Utility Model Content

[0005] In view of this, the present invention addresses the deficiencies of existing technologies, and its main objective is to provide a copper busbar conductive connector structure for new energy vehicles. By integrating the adhesive layer, mica layer, and PI layer, it achieves one-time, efficient coating of the metal connector, avoiding the gap problems of traditional winding methods, and enhancing insulation performance and product reliability. Simultaneously, it optimizes material usage, reduces waste, and effectively lowers production costs.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A conductive connector structure for copper busbars in new energy vehicles includes a metal connector and an insulating material component covering the outside of the metal connector for heat insulation and insulation. The insulating material component includes an adhesive layer, a mica layer, and a PI layer. The adhesive layer, mica layer, and PI layer are stacked sequentially from bottom to top. The PI layer covers the outside of the mica layer, and the mica layer is attached to the outer wall of the metal connector through the adhesive layer.

[0008] As a preferred embodiment, one side of the PI layer is at least flush with the mica layer.

[0009] As a preferred embodiment, one side of the PI layer extends beyond the mica layer.

[0010] As a preferred embodiment: the metal connecting piece includes a main body and connecting portions integrally connected to both ends of the main body; the mica layer includes a main body covering unit and connecting portion covering units connected to both ends of the main body covering unit, the main body covering unit covering the outer wall of the main body, and the connecting portion covering units covering the outer wall of the connecting portions; the PI layer covers the main body covering unit.

[0011] As a preferred embodiment: one side edge of the PI layer does not extend beyond the same side edge of the mica layer, forming a first distance between the two; the other side edge of the PI layer extends beyond the same side edge of the mica layer, forming a second distance between the two; the second distance is greater than the first distance.

[0012] As a preferred embodiment, the metal connecting piece has connecting holes on its connecting portions at both ends.

[0013] As a preferred embodiment: the connecting portions at both ends of the metal connecting piece respectively include a bent section and a contact section integrally connected to the bent section, and the connecting hole is hollowed out on the contact section; the insulating material component does not cover the outer wall of the contact section.

[0014] As a preferred embodiment: the length of the PI layer is less than the length of the main covering unit of the mica layer; the area of ​​the adhesive layer is the same as that of the mica layer.

[0015] As a preferred embodiment: the distance between one end of the PI layer and the same side end of the main body covering unit is 14 to 14.64 mm, and the distance between the other end of the PI layer and the other side end of the main body covering unit is 14.5 to 15.5 mm.

[0016] As a preferred embodiment, the connecting portion covering unit has multiple branches covering the outer wall of the connecting portion of the metal connecting piece.

[0017] Compared with existing technologies, this invention has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, by combining the adhesive layer, mica layer, and PI layer into a single layer, a breakthrough in one-time wrapping of metal connecting pieces is achieved. This insulating material not only improves wrapping efficiency and avoids the joint gaps that easily occur in traditional layer-by-layer wrapping, but also ensures the continuity and integrity of the insulating material, significantly improving the insulation performance and reliability of the product. Furthermore, the integrated layered wrapping technology is more economical in terms of material usage, reducing repeated wrapping, avoiding material waste, and lowering costs. This not only saves companies direct material costs but is also more energy-efficient and environmentally friendly.

[0018] To more clearly illustrate the structural features and effects of this utility model, the following detailed description is provided in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the conductive connecting piece of this utility model;

[0020] Figure 2 This is a schematic diagram of the cross-section of the conductive connecting piece of this utility model;

[0021] Figure 3 This is a schematic diagram of the planar distribution of the mica layer and PI layer of this utility model;

[0022] Figure 4 This is a three-dimensional structural diagram of the metal connecting piece of this utility model.

[0023] Explanation of reference numerals in the attached diagram:

[0024] 10. Metal connecting piece; 11. Main body; 12. Connecting part; 121. Connecting hole; 122. Bending section; 123. Contact section; 20. Insulating material part; 21. Adhesive layer; 22. Mica layer; 221. Main body covering unit; 222. Connecting part covering unit; 223. Branch part; 23. PI layer. Detailed Implementation

[0025] This utility model is as follows Figures 1 to 4 As shown, a copper busbar conductive connector structure for new energy vehicles includes a metal connector 10 and an insulating material 20 covering the outside of the metal connector 10 for heat insulation and insulation, wherein:

[0026] The metal connecting piece 10 includes a main body 11 and connecting parts 12 integrally connected to both ends of the main body 11; the connecting parts 12 at both ends of the metal connecting piece 10 respectively include a bent section 122 and a contact section 123 integrally connected to the bent section 122, and connecting holes 121 are respectively hollowed out on the contact sections 123 at both ends of the metal connecting piece 10; the insulating material component 20 does not cover the outer wall of the contact section 123.

[0027] The insulating material component 20 includes an adhesive layer 21, a mica layer 22, and a PI layer 23. The adhesive layer 21, the mica layer 22, and the PI layer 23 are stacked sequentially from bottom to top. The PI layer 23 covers the outside of the mica layer 22, and the mica layer 22 is attached to the outer wall of the metal connecting piece 10 through the adhesive layer 21.

[0028] The mica layer 22 includes a main covering unit 221 and connecting covering units 222 connected to both ends of the main covering unit 221. The main covering unit 221 covers the outer wall of the main body 11, and the connecting covering units 222 cover the outer wall of the connecting portion 12. The connecting covering unit 222 has multiple branches 223 covering the outer wall of the connecting portion 12 of the metal connecting piece 10. The PI layer 23 covers the main covering unit 221.

[0029] The PI layer 23 is flush with the mica layer 22 on one side; in this embodiment, the area of ​​the main body covering unit 221 of the mica layer 22 is larger than the area of ​​the metal connecting piece 10 including the main body 11, so as to completely cover the area of ​​the main body 11. The PI layer 23 extends beyond the mica layer 22 on one side. Specifically, the edge of the PI layer 23 on one side does not extend beyond the edge of the mica layer 22 on the same side (which saves material on the PI layer 23), forming a first distance A = 4 mm between them. The edge of the PI layer 23 on the other side extends beyond the edge of the mica layer 22 on the same side, forming a second distance B = 6 to 6.2 mm between them. The second distance is greater than the first distance, so that after the main body covering unit 221 of the mica layer 22 completely covers the main body 11, the part of the PI layer 23 that extends beyond the mica layer 22 (the part corresponding to the second distance) can completely cover the part that does not extend beyond the mica layer 22 (the part corresponding to the first distance), so that the PI layer 23 is connected end to end, achieving a seamless connection between the mica layer 22 and the PI layer 23, improving the insulation effect, and avoiding the material waste caused by the repeated winding of traditional insulation materials at the layer-to-layer junction. With one side of the PI layer 23 extending beyond the same edge as the mica layer 22, and with B being greater than A, the PI layer 23 can completely cover the mica layer 22 after the insulating material component 20 is wrapped around the metal connecting piece 10, thus avoiding gaps at the junction of the two layers and improving the insulation effect.

[0030] The length of the PI layer 23 is less than the length of the main covering unit 221 of the mica layer 22. Specifically, the distance between one end of the PI layer 23 and the same-side end of the main covering unit 221 is C = 14~14.64mm, and the distance between the other end of the PI layer 23 and the other-side end of the main covering unit 221 is D = 14.5~15.5mm. The adhesive layer 21 has the same area as the mica layer 22, so that the mica layer 22 can be completely attached to the outer wall of the metal connecting piece 10.

[0031] When covering the metal connecting piece 10 with the insulating material 20, the insulating material 20 can be directly wrapped around the main body 11 and the connecting part 12 of the metal connecting piece 10.

[0032] The key design feature of this invention lies in its breakthrough in one-time wrapping of metal connecting pieces by integrating the adhesive layer, mica layer, and PI layer in a stacked manner. This insulating material not only improves wrapping efficiency and avoids the gaps that easily occur in traditional layer-by-layer wrapping, but also ensures the continuity and integrity of the insulating material, significantly enhancing the insulation performance and reliability of the product. Furthermore, the integrated stacked wrapping technology is more economical in terms of material usage, reducing repeated wrapping, avoiding material waste, and lowering costs. This not only saves companies direct material expenses but is also more energy-efficient and environmentally friendly.

[0033] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the technical scope of the present utility model. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model shall still fall within the scope of the technical solution of the present utility model.

Claims

1. A copper busbar conductive connector structure for new energy vehicles, characterized in that: The device includes a metal connecting piece and an insulating material component covering the outside of the metal connecting piece for heat insulation and insulation. The insulating material component includes an adhesive layer, a mica layer and a PI layer. The adhesive layer, mica layer and PI layer are stacked sequentially from bottom to top. The PI layer covers the outside of the mica layer. The mica layer is attached to the outer wall of the metal connecting piece through the adhesive layer.

2. The new energy vehicle copper busbar conductive connector structure according to claim 1, characterized in that: One side of the PI layer is at least flush with the mica layer.

3. The new energy vehicle copper busbar conductive connector structure according to claim 1, characterized in that: The PI layer extends beyond the mica layer on one side.

4. The new energy vehicle copper busbar conductive connector structure according to claim 1, characterized in that: The metal connecting piece includes a main body and connecting parts integrally connected to both ends of the main body; the mica layer includes a main body covering unit and connecting part covering units connected to both ends of the main body covering unit, the main body covering unit covers the outer wall of the main body, and the connecting part covering unit covers the outer wall of the connecting part; the PI layer covers the main body covering unit.

5. The new energy vehicle copper busbar conductive connector structure according to claim 3, characterized in that: One edge of the PI layer does not extend beyond the same edge of the mica layer, forming a first distance between them; the other edge of the PI layer extends beyond the same edge of the mica layer, forming a second distance between them; the second distance is greater than the first distance.

6. The new energy vehicle copper busbar conductive connector structure according to claim 4, characterized in that: The metal connecting piece has connecting holes at both ends of its connecting portion.

7. The new energy vehicle copper busbar conductive connector structure according to claim 6, characterized in that: The connecting portions at both ends of the metal connecting piece include a bent section and a contact section integrally connected to the bent section, respectively, and the connecting hole is hollowed out on the contact section; the insulating material does not cover the outer wall of the contact section.

8. The new energy vehicle copper busbar conductive connector structure according to claim 4, characterized in that: The length of the PI layer is less than the length of the main covering unit of the mica layer; the area of ​​the adhesive layer is the same as that of the mica layer.

9. The new energy vehicle copper busbar conductive connector structure according to claim 4, characterized in that: The distance between one end of the PI layer and the same-side end of the main body covering unit is 14 to 14.64 mm, and the distance between the other end of the PI layer and the other-side end of the main body covering unit is 14.5 to 15.5 mm.

10. The new energy vehicle copper busbar conductive connector structure according to claim 4, characterized in that: The connecting part covering unit has multiple branches covering the outer wall of the connecting part of the metal connecting piece.

Images