Novel high-pressure injection molding copper bar structure for high-power compact fuel cell stack

Abstract

The utility model relates to a novel high-pressure injection molding copper bar structure for a high-power compact fuel cell stack in the field of fuel cell structure design, which comprises an anode conductive copper bar, a cathode conductive copper bar and an insulating mounting body, and the anode conductive copper bar and the cathode conductive copper bar are arranged above the insulating mounting body. The positive conductive copper bar and the negative conductive copper bar are symmetrically arranged along the central axis of the insulating mounting body, the positive conductive copper bar, the negative conductive copper bar and the insulating mounting body are in sealed connection by adopting an injection molding process, and gaps are formed between the positive conductive copper bar and the insulating mounting body and between the negative conductive copper bar and the insulating mounting body and are sealed by adopting glue. Compared with the prior art, by changing the forming process, eliminating the gap between the conductive copper bar and the insulation installation body, increasing the contact area between the conductive copper bar and the insulation installation body and adopting the mode of reasonably distributing the sealing glue injection grooves, the sealing problem of the high-voltage copper bar is solved, and potential safety hazards are eliminated.

Description

Technical Field

[0001] This utility model relates to the field of fuel cell structural design, and in particular to a novel high-pressure injection-molded copper busbar structure for high-power compact fuel cell stacks. Background Technology

[0002] Battery energy storage cabinets are advanced integrated devices that include components such as batteries, electronic controllers, and sensors, used to store and release electrical energy. However, existing battery energy storage cabinets have some technical shortcomings in their circuit systems, mainly in the management and monitoring of circuit breakers.

[0003] In existing technologies, fuel cell stacks generate current through electrochemical reactions. This current needs to be transmitted to a DC-DC converter via a high-voltage copper busbar. After conversion by the DC-DC converter, it is then distributed to various user units for application. The sealing design of the high-voltage copper busbar is critical because it is directly connected to the DC-DC converter. If hydrogen leaks inside the stack and the high-voltage copper busbar is not properly sealed, hydrogen may enter the DC-DC converter. If it then encounters the opening and closing discharge of electrical contact elements, it may pose a safety hazard of deflagration.

[0004] In existing designs and manufacturing processes, the conductive copper busbars and insulating mounting bodies of high-voltage copper busbars are manufactured separately through machining, then assembled together, and sealant is applied to the gaps for sealing. This structure and forming process can easily lead to seal failure of the high-voltage copper busbars during use, thus creating safety hazards. Utility Model Content

[0005] In view of this, this utility model proposes a novel high-pressure injection-molded copper busbar structure for high-power compact fuel cell stacks, which can tightly bond the conductive copper busbar and the insulating mounting body, eliminating the gap between the conductive copper busbar and the insulating mounting body, and improving the sealing requirements of the fuel cell stack packaging. The technical solution of this utility model is as follows:

[0006] This invention proposes a novel high-pressure injection-molded copper busbar structure for a high-power compact fuel cell stack, comprising a positive electrode conductive copper busbar, a negative electrode conductive copper busbar, and an insulating mounting body.

[0007] Specifically, the positive conductive copper busbar and the negative conductive copper busbar are disposed above the insulating mounting body. The positive conductive copper busbar and the negative conductive copper busbar are symmetrically arranged along the central axis of the insulating mounting body. The positive conductive copper busbar and the negative conductive copper busbar are sealed to the insulating mounting body by injection molding. There is a gap between the positive conductive copper busbar and the negative conductive copper busbar and the insulating mounting body, and the gap is sealed by applying adhesive.

[0008] Specifically, the insulating mounting body is provided with a first boss and a second boss, which are symmetrically arranged along the central axis of the insulating mounting body.

[0009] Furthermore, the positive conductive copper busbar is connected to the first boss, and the negative conductive copper busbar is connected to the second boss.

[0010] Specifically, the first boss includes a first bolt, a second bolt, a first washer, a second washer, a first end cap, and a first sealing ring. The first bolt and the second bolt pass through the first end cap to connect to the insulating mounting body.

[0011] Furthermore, a first gasket is placed between the first bolt and the first end cap, a second gasket is placed between the second bolt and the first end cap, and a first sealing ring is placed between the first end cap and the insulating mounting body.

[0012] Specifically, the second boss includes a third bolt, a fourth bolt, a third washer, a fourth washer, a second end cap, and a second sealing ring. The third bolt and the fourth bolt pass through the second end cap and connect to the insulating mounting body.

[0013] Furthermore, a third gasket is placed between the third bolt and the second end cap, a fourth gasket is placed between the fourth bolt and the second end cap, and a second sealing ring is placed between the second end cap and the insulating mounting body.

[0014] Specifically, a slot is provided on the top of the insulating mounting body, the slot is located on one side of the surface of the insulating mounting body, and the slot is arranged around the positive conductive copper busbar and the negative conductive copper busbar.

[0015] Specifically, the positive conductive copper busbar is provided with a first circular hole and a second circular hole, which are arranged vertically along the central axis of the positive conductive copper busbar.

[0016] Specifically, the negative electrode conductive copper busbar is provided with a third circular hole and a fourth circular hole, which are arranged vertically along the central axis of the negative electrode conductive copper busbar.

[0017] The advantages of this utility model are as follows:

[0018] 1. This utility model replaces the traditional machining and post-assembly processes with an injection molding process, eliminating the gap between the conductive copper busbar and the insulating mounting body, increasing the contact area, ensuring efficient current conduction, and meeting high-voltage insulation requirements, thus greatly improving the performance and reliability of the conductive copper busbar.

[0019] 2. This utility model adds a flat groove and two bosses, significantly increasing the creepage distance and thus improving insulation safety. Secondly, the use of a larger area of ​​internal adhesive sealing effectively solves the sealing problem of the high-voltage copper busbar, completely eliminating safety hazards.

[0020] 3. This utility model simplifies the production management process by reducing the number of fuel cell stack parts. The use of injection molding makes the structure more compact, facilitating installation and production, and making management and maintenance more efficient.

[0021] 4. The parts of this invention can be inspected individually, ensuring that each part is qualified before assembly, reducing overall assembly time and improving production line efficiency. This not only saves time but also improves the controllability of product quality.

[0022] 5. This utility model reduces production costs through improved process design, creating favorable conditions for mass production. This cost saving not only improves economic efficiency but also promotes the further development of the fuel cell industry. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one embodiment of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions toward or away from the geometric center of a specific part, respectively.

[0025] Figure 1 This is a front view of an embodiment of the present utility model;

[0026] Figure 2 This is a top view of an embodiment of the present utility model;

[0027] Figure 3 for Figure 2 BB section view in the middle.

[0028] The meanings of the reference numerals in the above figures are as follows:

[0029] 1. Positive conductive copper busbar;

[0030] 11. First circular hole; 12. Second circular hole;

[0031] 2. Negative conductive copper busbar;

[0032] 21. Third circular hole; 22. Fourth circular hole;

[0033] 3. Insulating mounting body;

[0034] 31. First boss;

[0035] 311. First bolt;

[0036] 312. Second bolt;

[0037] 313. First gasket;

[0038] 314. Second gasket;

[0039] 315. First end cap;

[0040] 316. First sealing ring;

[0041] 32. Second boss;

[0042] 321. The third bolt;

[0043] 322. Fourth bolt;

[0044] 323. Third gasket;

[0045] 324. Fourth gasket;

[0046] 325. Second end cap;

[0047] 326. Second sealing ring;

[0048] 33. Grooving;

[0049] 4. Gap. Detailed Implementation

[0050] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0051] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used in the detailed description is for the purpose of describing particular embodiments only and is not intended to limit the invention; the terms “comprising” and “having” and any variations thereof in the specification, claims and foregoing description of the invention are intended to cover non-exclusive inclusion.

[0052] In the description of the specific embodiments of this utility model, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this utility model, "multiple" means two or more, unless otherwise explicitly defined.

[0053] In this invention, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this invention. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this invention can be combined with other embodiments.

[0054] In the description of this utility model embodiment, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this utility model, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0055] Throughout this invention, numerical values ​​represent approximate measurements or limits of a range to cover minute deviations from a given value, as well as embodiments having approximately the mentioned value and embodiments having the exact mentioned value. Except for the working examples provided at the end of the detailed description, all numerical values ​​of parameters, quantities, or conditions in the appended claims should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows for some minute inaccuracy that is somewhat close to the exact value of the value; approximately or reasonably close to the value; almost. If the inaccuracy provided by “about” is not otherwise understood in this common sense in the art, then “about” as used in this invention at least indicates a variation that can be produced by common methods of measuring and using such parameters. For example, “about” may include a variation of less than or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally less than or equal to 1%, optionally less than or equal to 0.5%, and in some respects, optionally less than or equal to 0.1%.

[0056] Additionally, the disclosure of the range includes the disclosure of all values ​​across the entire range and the disclosure of further subdivided ranges, including the endpoints and subranges given for these ranges.

[0057] The embodiments of the present invention will be described in more detail below through examples. It should be noted that the embodiments of the present invention are not limited to these examples.

[0058] The current generated by the electrochemical reaction in existing fuel cell stacks needs to be transmitted to a DC-DC converter via a high-voltage copper busbar before being distributed to various user units. The high-voltage copper busbar is directly connected to the DC-DC converter. If there is a hydrogen leak inside the stack or the high-voltage copper busbar is poorly sealed, hydrogen may leak into the DC-DC converter. When this leak encounters the opening and closing of electrical contact elements, it could potentially cause a deflagration. In the current design and manufacturing process, the conductive copper busbar and the insulating mounting body of the high-voltage copper busbar are machined separately, then assembled and sealed with sealant at the gap. This structure and forming process can lead to sealing failure of the high-voltage copper busbar during use, posing a safety hazard.

[0059] To address the aforementioned issues, this invention proposes a novel high-voltage injection-molded copper busbar structure for high-power compact fuel cell stacks. While ensuring efficient current conduction and meeting high-voltage insulation requirements, the original machining and assembly process is modified to a one-piece injection molding process. This eliminates the gap between the conductive copper busbar and the insulating mounting body, increasing the contact area and ensuring effective sealing. The addition of planar grooves and two bosses increases the creepage distance and improves insulation safety. Furthermore, the internal adhesive sealing method effectively solves the sealing problem of the high-voltage copper busbar and eliminates safety hazards. Specific embodiments are as follows:

[0060] Example

[0061] In one specific embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, a circuit breaker detection circuit includes a positive conductive copper busbar 1, a negative conductive copper busbar 2, and an insulating mounting body 3. The positive conductive copper busbar 1 and the negative conductive copper busbar 2 are positioned above the insulating mounting body 3, symmetrically arranged along the central axis of the insulating mounting body 3. The positive conductive copper busbar 1 and the negative conductive copper busbar 2 are sealed to the insulating mounting body 3 using an injection molding process. A gap 4 exists between the positive conductive copper busbar 1 and the negative conductive copper busbar 2 and the insulating mounting body 3, and this gap 4 is sealed with adhesive. This arrangement increases the area of ​​the internal adhesive coating, strengthens the adhesion, and makes the seal more reliable.

[0062] With the above setup, the positive conductive copper busbar 1, the negative conductive copper busbar 2, and the insulating mounting body 3 are formed into a single part by injection molding process, with a large contact area and no gaps 4.

[0063] In this embodiment, the insulating mounting body 3 is provided with a first boss 31 and a second boss 32. The first boss 31 and the second boss 32 are symmetrically arranged along the central axis of the insulating mounting body 3. The addition of two bosses is used to increase the creepage distance and improve the insulation performance.

[0064] In some embodiments, the positive conductive copper busbar 1 is connected to the first boss 31, and the negative conductive copper busbar 2 is connected to the second boss 32.

[0065] In some specific embodiments, the first boss 31 includes a first bolt 311, a second bolt 312, a first gasket 313, a second gasket 314, a first end cap 315, and a first sealing ring 316. The first bolt 311 and the second bolt 312 pass through the first end cap 315 and are connected to the insulating mounting body 3.

[0066] In some specific embodiments, a first gasket 313 is placed between the first bolt 311 and the first end cap 315, a second gasket 314 is placed between the second bolt 312 and the first end cap 315, and a first sealing ring 316 is placed between the first end cap 315 and the insulating mounting body 3.

[0067] In some specific embodiments, the second boss 32 includes a third bolt 321, a fourth bolt 322, a third gasket 323, a fourth gasket 324, a second end cap 325, and a second sealing ring 326. The third bolt 321 and the fourth bolt 322 pass through the second end cap 325 and connect to the insulating mounting body 3.

[0068] In some specific embodiments, a third gasket 323 is placed between the third bolt 321 and the second end cap 325, a fourth gasket 324 is placed between the fourth bolt 322 and the second end cap 325, and a second sealing ring 326 is placed between the second end cap 325 and the insulating mounting body 3.

[0069] In this embodiment, a slot 33 is provided on the upper part of the insulating mounting body 3. The slot 33 is located on one side of the surface of the insulating mounting body 3 and is arranged around the positive conductive copper busbar 1 and the negative conductive copper busbar 2. The slot 33 is used to increase the creepage distance and improve the insulation performance.

[0070] In some embodiments, the positive electrode conductive copper busbar 1 is provided with a first circular hole 11 and a second circular hole 12, which are arranged vertically along the central axis of the positive electrode conductive copper busbar 1.

[0071] In some embodiments, the negative electrode conductive copper busbar 2 is provided with a third circular hole 21 and a fourth circular hole 22, which are arranged vertically along the central axis of the negative electrode conductive copper busbar 2.

[0072] It should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A novel high-pressure injection-molded copper busbar structure for a high-power compact fuel cell stack, characterized in that, Includes positive conductive copper busbar, negative conductive copper busbar, and insulating mounting body; The positive conductive copper busbar and the negative conductive copper busbar are disposed above the insulating mounting body, and the positive conductive copper busbar and the negative conductive copper busbar are symmetrically arranged along the central axis of the insulating mounting body; The positive conductive copper busbar, the negative conductive copper busbar, and the insulating mounting body are sealed together by injection molding. There is a gap between the positive conductive copper busbar, the negative conductive copper busbar, and the insulating mounting body, and the gap is sealed with adhesive.

2. The novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 1, characterized in that, The insulating mounting body is provided with a first boss and a second boss, which are arranged symmetrically along the central axis of the insulating mounting body.

3. The novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 2, characterized in that, The positive conductive copper busbar is connected to the first boss, and the negative conductive copper busbar is connected to the second boss.

4. The novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 3, characterized in that, The first boss includes a first bolt, a second bolt, a first washer, a second washer, a first end cap, and a first sealing ring. The first bolt and the second bolt pass through the first end cap and connect to the insulating mounting body.

5. The novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 4, characterized in that, The first gasket is placed between the first bolt and the first end cap, the second gasket is placed between the second bolt and the first end cap, and the first sealing ring is placed between the first end cap and the insulating mounting body.

6. The novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 3, characterized in that, The second boss includes a third bolt, a fourth bolt, a third washer, a fourth washer, a second end cap, and a second sealing ring. The third bolt and the fourth bolt pass through the second end cap and connect to the insulating mounting body.

7. A novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claim 6, characterized in that, The third gasket is placed between the third bolt and the second end cap, the fourth gasket is placed between the fourth bolt and the second end cap, and the second sealing ring is placed between the second end cap and the insulating mounting body.

8. A novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claims 1-7, characterized in that, A slot is provided on the top of the insulating mounting body. The slot is located on one side of the surface of the insulating mounting body and is arranged around the positive conductive copper busbar and the negative conductive copper busbar.

9. A novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claims 1-7, characterized in that, The positive conductive copper busbar is provided with a first circular hole and a second circular hole, which are arranged vertically along the central axis of the positive conductive copper busbar.

10. A novel high-power compact fuel cell stack high-pressure injection-molded copper busbar structure according to claims 1-7, characterized in that, The negative conductive copper busbar is provided with a third circular hole and a fourth circular hole, which are arranged vertically along the central axis of the negative conductive copper busbar.

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