High-voltage busbar

Abstract

The utility model relates to the technical field of high-voltage busbars, and discloses a high-voltage busbar which comprises a core wire bar, a composite layer, a pressure-resistant layer and a wear-resistant layer are sequentially arranged on the outer side of the core wire bar, the composite layer is arranged on the outer side of the core wire bar in a plastic coating mode and used for improving insulation, high temperature resistance and flame retardance of the busbar, the pressure-resistant layer is fixed between the composite layer and the wear-resistant layer, and the wear-resistant layer is fixed between the composite layer and the wear-resistant layer. The core wire bar is used for improving the compression strength of the busbar and is one of a copper bar and an aluminum bar; the composite layer is made of a mixed material of ceramic silica gel and mica powder; the pressure-resistant layer is made of a PI material or a mica paper material; and the wear-resistant layer is made of a TPU material. According to the utility model, the composite layer, the pressure-resistant layer and the wear-resistant layer are coated outside the core wire row, so that the requirements of high voltage, insulation, pressure resistance, wear resistance and the like of the busbar are met, the busbar is ensured to be safely used on a high-voltage line on an automobile, the use process is stable, the service life is long, the production process is simple to operate, the material cost and the process cost are lower, and the production efficiency is improved. And the actual busbar batch production requirement is met.

Description

TECHNICAL FIELD

[0001] The utility model relates to high -pressure busbar technical field, specifically a kind of high -pressure busbar. BACKGROUND

[0002] The application of busbar in the field of new energy vehicles is mainly used for power battery module connection and inverter connection scene. The busbar is composed of inner layer conductive material copper bar or aluminum bar and outer layer insulating material.

[0003] In the prior art, such as the application number: CN202321849510.7 disclosed in the name: copper bar assembly, busbar, motor and automobile, which includes a first copper bar body, the first copper bar body includes a main body segment and a heat conducting segment connected to the main body segment, the temperature measuring assembly includes a sheath and a temperature sensor, the sheath is clamped and fixed with the heat conducting segment to form a clamping space to clamp and fix the temperature sensor.

[0004] However, the busbar mentioned in the prior art is difficult to meet the performance requirements of automobile busbar in actual production by using a single material to form an insulating outer layer. Using multiple materials and processes to meet the use requirements will increase production costs, so a high-voltage busbar needs to be designed. UTILITY MODEL CONTENTS

[0005] The utility model aims to provide a kind of high-voltage busbar to solve the problems in the prior art.

[0006] The purpose of the utility model can be achieved by the following technical solutions:

[0007] A kind of high-voltage busbar, the busbar includes core wire row, the outside of the core wire row is sequentially provided with composite layer, voltage resistance layer and wear-resistant layer, the composite layer is plastic-coated and arranged on the outside of the core wire row, to improve the insulation, high-temperature resistance and flame retardance of the busbar, the voltage resistance layer is fixed between the composite layer and the wear-resistant layer, to improve the voltage resistance strength of the busbar, the outside of the voltage resistance layer is wrapped with wear-resistant layer with elasticity and high wear resistance, to improve the wear frequency of the high-voltage busbar.

[0008] Further, the core wire row is one of copper bar and aluminum bar.

[0009] The composite layer is made of ceramic silica gel and mica powder mixed material.

[0010] The voltage resistance layer is made of PI material or mica paper material.

[0011] The wear-resistant layer is made of TPU material.

[0012] Further, the core wire row is arrayed with through slot, to separate the core wire row, the outside of the wear-resistant layer is provided with a plurality of grooves, to bend the busbar.

[0013] Further, the composite layer is provided with two parallel core wire rows, and a pad layer is fixedly arranged between the two core wire rows to separate the two core wire rows.

[0014] Further, the pad layer is provided with two insulating layers, and a fire-retardant layer and a reinforcing layer are fixedly arranged between the two insulating layers, one side of the fire-retardant layer is connected with the reinforcing layer, and the other side is connected with the insulating layer.

[0015] Further, the insulating layer is made of ceramic silica gel material, the thickness is 0.2-0.4 mm, the fire-retardant layer is made of PI material or mica paper material, the thickness is 0.05-0.20 mm, and the reinforcing layer is made of TPU material, the thickness is 0.3-0.6 mm.

[0016] The high-voltage bus bar has the advantages that:

[0017] 1. The high-voltage bus bar is provided with a composite layer, a voltage-resistant layer and a wear-resistant layer on the outer side of the core wire row, so as to meet the requirements of high voltage, insulation, pressure resistance and wear resistance of the bus bar, ensure the safe use of the bus bar on the high-voltage line of the automobile, and have stable use process and long service life.

[0018] 2. The high-voltage bus bar has simple structure, simple production process operation and simple material acquisition, so that the material cost and process cost are low, the actual bus bar batch production demand is met, and the actual use demand of the bus bar is met. BRIEF DESCRIPTION OF DRAWINGS

[0019] The utility model will be further described below in combination with the drawings.

[0020] Figure 1 is the bus bar structure schematic view of the utility model;

[0021] Figure 2 is the bus bar structure schematic view of the utility model;

[0022] Figure 3 is the bus bar sectional structure schematic view of the utility model;

[0023] Figure 4 is the bus bar internal structure schematic view of the utility model;

[0024] Figure 5 is the pad layer structure schematic view of the utility model. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the utility model.

[0026] Embodiment 1

[0027] A kind of high-voltage busbar, it is mainly used in high-voltage environment, such as Figure 1 As shown in the figure, the busbar includes core wire row 1, which is made of conductive material, mainly one of copper row and aluminum row, the outer side of the core wire row 1 is sequentially provided with composite layer 2, voltage resistance layer 3 and wear-resistant layer 4, the composite layer 2 is plastic molded on the outer side of the core wire row 1, and the voltage resistance layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0028] In this embodiment, the composite layer 2 is made of ceramic silica gel and mica powder mixed material, mainly molded by extrusion processing on the outer side of the core wire row 1, the ceramic silica gel and mica powder material has ultrahigh insulation performance and high temperature resistance characteristics, which is an inorganic insulating material, can resist high temperature above 800 DEG C, and has high voltage resistance strength and is not easy to break down, so that the prepared busbar has insulation voltage resistance not less than 3000V after high temperature baking.

[0029] In this embodiment, the voltage resistance layer 3 is made of PI material or mica paper material, mainly by winding processing, polyimide film or mica paper is wound and packaged on the composite layer 2, at least one layer is wound, which is used to form a voltage resistance protection structure on the outer side of the composite layer 2, to protect the inner ceramic silica gel material and improve the insulation voltage resistance.

[0030] In this embodiment, the wear-resistant layer 4 is made of TPU material, mainly by extrusion processing to form thermoplastic polyurethane elastomer on the outer side of the voltage resistance layer 3, which has elasticity and super high wear resistance, and the wear resistance times is more than twice of the existing wire row.

[0031] Beneficial effects: the outer side of the core wire row 1 is sequentially provided with the composite layer 2 made of ceramic silica gel and mica powder, the voltage resistance layer 3 made of PI material or mica paper material, and the wear-resistant layer 4 made of TPU, the composite layer 2 is used to improve the insulation performance and high temperature resistance, flame resistance of the busbar, to meet the use in high temperature and high pressure environment.

[0032] And the voltage resistance layer 3 protects the inner ceramic silica gel material and improves the insulation voltage resistance, the wear-resistant layer 4 has elasticity and super wear resistance, the first layer of plastic material has low cost, and the extrusion process can be continuously produced, which can save 40% of the material and production cost.

[0033] Embodiment 2

[0034] A high-voltage bus bar, mainly used in high-voltage environments, such as Figure 1 As shown, the bus bar includes a core wire row 1 made of conductive material, mainly one of copper row and aluminum row, and the outer side of the core wire row 1 is sequentially provided with a composite layer 2, a voltage-resistant layer 3 and a wear-resistant layer 4. The composite layer 2 is over-molded on the outer side of the core wire row 1, and the voltage-resistant layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0035] In this embodiment, the composite layer 2 is made of a mixed material of ceramic silica gel and mica powder, and is over-molded on the outer side of the core wire row 1 mainly by extrusion processing. The ceramic silica gel and mica powder material has ultra-high insulation performance and high-temperature resistance characteristics, and is an inorganic insulating material that can withstand high temperatures above 800°C and has high voltage resistance and is not easy to break down, so that the prepared bus bar has an insulation voltage resistance of not less than 3000V after high-temperature baking.

[0036] In this embodiment, the voltage-resistant layer 3 is made of PI material or mica paper material, and is mainly wound and packaged on the composite layer 2 by winding processing. The polyimide film or mica paper is wound at least one layer to form a voltage-resistant protective structure on the outer side of the composite layer 2, which serves to protect the inner ceramic silica gel material and improve the insulation voltage resistance.

[0037] In this embodiment, the wear-resistant layer 4 is made of TPU material, and is mainly formed on the outer side of the voltage-resistant layer 3 by extrusion processing. It has elasticity and ultra-high wear resistance, and the wear-resistant times are more than twice that of existing wire rows.

[0038] As shown in Figure 2 , Figure 3 The core wire row 1 is provided with array-distributed through grooves 11. After the bus bar is cut off at the through grooves 11, the outer wrapping structure is stripped off, and the core wire row 1 can be divided into two wiring ends at the through grooves 11, which is convenient for actual wiring use.

[0039] The outer side of the wear-resistant layer 4 is provided with a plurality of recesses 41, which are annularly arranged on the outer side of the wear-resistant layer 4, facilitating the bending use of the core wire row 1. The two ends of the through groove 11 are respectively provided with recesses 41, so that the position of the through groove 11 can be identified and confirmed during actual use.

[0040] In actual use, when the bus bar needs to be connected separately, the core wire row 1 of the bus bar is cut off at the two recesses 41 and bent at the through groove 11 for separate connection, without the need for additional cutting operation. At the same time, the bending at the recess 41 can reduce the wrinkles of the wear-resistant layer 4 after bending, and the bending wiring operation of the bus bar is labor-saving.

[0041] Embodiment 3:

[0042] A high-voltage bus bar, mainly used in high-voltage environments, such asFigure 1 As shown, the busbar includes a core wire row 1 made of conductive material, mainly one of copper row and aluminum row, and the outer side of the core wire row 1 is sequentially provided with a composite layer 2, a voltage resistance layer 3 and a wear-resistant layer 4. The composite layer 2 is over-molded on the outer side of the core wire row 1, and the voltage resistance layer 3 is fixed between the composite layer 2 and the wear-resistant layer 4.

[0043] In this embodiment, the composite layer 2 is made of a mixed material of ceramic silica gel and mica powder, mainly over-molded on the outer side of the core wire row 1 by an extrusion processing technology. The ceramic silica gel and mica powder material has super-high insulation performance and high-temperature resistance characteristics, is an inorganic insulating material, can resist high temperature above 800℃, and has high voltage resistance strength and is not easy to break down, so that the prepared busbar has an insulation voltage resistance of not less than 3000V after high-temperature baking.

[0044] In this embodiment, the voltage resistance layer 3 is made of PI material or mica paper material, mainly by winding processing, and the polyimide film is wound and packaged on the composite layer 2, at least one layer, for forming a voltage resistance protection structure on the outer side of the composite layer 2, to protect the inner ceramic silica gel material and improve the insulation voltage resistance.

[0045] In this embodiment, the wear-resistant layer 4 is made of TPU material, mainly by extrusion processing to form a thermoplastic polyurethane elastomer on the outer side of the voltage resistance layer 3, which has elasticity and super-high wear resistance, and the wear-resistant times are more than twice of the existing wire row.

[0046] As shown, Figure 4 The composite layer 2 is provided with two parallel core wire rows 1, at least one of which is used for transmission, and a pad layer 5 is fixedly arranged between the two core wire rows 1, which is used for separating the two core wire rows 1.

[0047] The pad layer 5 is made of two layers of insulation layers 51, and a flame-retardant layer 52 and a reinforcing layer 53 are fixedly arranged between the two layers of insulation layers 51, one side of the flame-retardant layer 52 is attached to the reinforcing layer 53, and the other side is attached to the insulation layer 51.

[0048] The insulation layer 51 is made of ceramic silica gel material and has insulation performance, with a thickness of 0.2-0.4mm, the flame-retardant layer 52 is made of PI material or mica paper material and has flame-retardant effect and insulation effect, with a thickness of 0.05-0.20mm, and the reinforcing layer 53 is made of TPU material and has insulation and tensile effect, with a thickness of 0.3-0.6mm.

[0049] The pad layer 5 is arranged between the two core wire rows 1 to separate and insulate the two core wire rows 1, to ensure that the two core wire rows 1 work independently and stably without interference, and to improve the working life of the busbar in a large current and high voltage environment.

[0050] Under the condition of the conventional use temperature interval of-40 DEG C ~ 125 DEG C, two comparative examples are increased to compare with the busbar of the utility model, as follows:

[0051] Comparative example one, the design of conductor + insulation layer, the insulation layer is usually PA11 / PA12;

[0052] Comparative example one usually lacks high-temperature insulation performance test, and the defects are: no high-temperature resistant flame-retardant material, unable to meet the insulation performance requirement after thermal runaway of the power battery, and the application end needs to additionally increase the high-temperature resistant flame-retardant material to compensate.

[0053] Comparative example two, the design of conductor + mica layer + insulation layer, the insulation layer is usually PA11 / PA12.

[0054] Comparative example two meets the 400 DEG C short-term high-temperature insulation performance (1H test);

[0055] Test requirement: after 400 DEG C high-temperature baking, the leakage current is less than 10 mA, and the maximum withstand voltage value is confirmed;

[0056] Actual test: the maximum withstand voltage is 2KV ~ 2.5KV.

[0057] The high-voltage busbar of the utility model meets the 400 DEG C short-term high-temperature insulation performance (1H test);

[0058] Test requirement: after 400 DEG C high-temperature baking, the leakage current is less than 10 mA, and the maximum withstand voltage value is confirmed;

[0059] Actual test: the maximum withstand voltage is 3KV ~ 3.5KV.

[0060] The high-voltage busbar of the utility model has the advantages that the high-temperature insulation flame-retardant requirement is met, and the ceramic silica gel layer improves the high-temperature insulation performance; the ceramic silica gel layer adopts an integrated extrusion mode, the material cost is low, the material utilization rate is high, and the material production process is environmentally friendly.

[0061] The above shows and describes the basic principle, main features and advantages of the utility model. It should be understood by those skilled in the art that the utility model is not limited by the above examples, and the above examples and descriptions in the specification are only to illustrate the principle of the utility model, and various changes and improvements can be made to the utility model without departing from the spirit and scope of the utility model, and these changes and improvements all fall within the scope of the utility model claimed.

Claims

1. A high-voltage busbar, the busbar comprising a core wire arrangement (1), characterized in that, The outer side of the core wire row (1) is sequentially provided with a composite layer (2), a voltage resistance layer (3) and a wear-resistant layer (4), the composite layer (2) is wrapped on the outer side of the core wire row (1), and is used for improving the insulation, high temperature resistance and flame resistance of the bus bar, the voltage resistance layer (3) is fixed between the composite layer (2) and the wear-resistant layer (4), and is used for improving the voltage resistance strength of the bus bar, and the outer side of the voltage resistance layer (3) is wrapped with the wear-resistant layer (4) with elasticity and high wear resistance, so that the wear-resistant times of the high-voltage bus bar are improved.

2. A high voltage busbar according to claim 1, characterized in that The core wire row (1) is one of a copper row and an aluminum row; The composite layer (2) is made of a mixed material of ceramic silica gel and mica powder; The voltage resistance layer (3) is made of PI material or mica paper material; The wear-resistant layer (4) is made of TPU material.

3. A high voltage busbar according to claim 1, characterized in that The core wire row (1) is provided with a through groove (11) in an array, which is used for separating the core wire row (1), and the outer side of the wear-resistant layer (4) is provided with a plurality of grooves (41), which are used for bending the bus bar.

4. A high voltage busbar according to claim 1, characterized in that The composite layer (2) is provided with two core wire rows (1) arranged in parallel, and a cushion layer (5) is fixed between the two core wire rows (1) and is used for separating the two core wire rows (1).

5. A high voltage busbar according to claim 4, characterized in that The cushion layer (5) is made of two insulating layers (51), and a fire-retardant layer (52) and a reinforcing layer (53) are fixed between the two insulating layers (51), one side of the fire-retardant layer (52) is connected with the reinforcing layer (53), and the other side is connected with the insulating layer (51).

6. A high voltage busbar according to claim 5, characterized in that The insulating layer (51) is made of ceramic silica gel material, has a thickness of 0.2-0.4mm, the fire-retardant layer (52) is made of PI material or mica paper material, has a thickness of 0.05-0.20mm, and the reinforcing layer (53) is made of TPU material, has a thickness of 0.3-0.6mm.

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