Fireproof injection molding busbar

Abstract

The utility model relates to a fire-resistant injection molding busbar, and relates to the technical field of conductive connecting pieces, the fire-resistant injection molding busbar comprises a bus conductor formed by processing, a plurality of support clips distributed along the length direction of the bus conductor and a fire-resistant insulating layer wrapping the bus conductor and the support clips, the support clips are distributed on two sides of the bus conductor, and the fire-resistant insulating layer is arranged on the bus conductor. Two ends of the bus conductor are exposed from two ends of the fire-resistant insulating layer, the cross section of the support clip is U-shaped, three side plates respectively abut against the upper surface, the lower surface and the side surface of the bus conductor, thickness limiting protrusions are arranged on the outer surfaces of the three side plates of the support clip, and the top surfaces of the thickness limiting protrusions are flush with the outer surface of the fire-resistant insulating layer around the fire-resistant insulating layer. The busbar processing precision is easy to control, the automation degree is high, multi-dimensional forming can be achieved, the structure is reasonable and compact, the appearance is attractive and elegant, and good fire resistance and insulativity are achieved.

Description

Technical Field

[0001] This application relates to the technical field of conductive connectors, and in particular to a fire-resistant injection-molded busbar. Background Technology

[0002] With the rapid growth in the number of new energy vehicles, related safety accidents have also gradually increased, becoming a focus of consumer attention. GB / T18384-2015 "Safety Requirements for Electric Vehicles" is the basic standard upon which electric vehicle design is based, providing comprehensive and fundamental safety requirements for electric vehicles. Meanwhile, GB38031-2020 "Safety Requirements for Power Batteries for Electric Vehicles - Battery Pack or System Safety Requirements" has also been released, requiring that the battery pack or system provide a thermal event alarm signal 5 minutes before thermal runaway of a single battery causes thermal diffusion, leading to a hazard in the passenger compartment.

[0003] A related technology discloses a refractory extruded busbar, comprising: a busbar layer, a refractory layer, and an insulating layer; the surface of the busbar layer is entirely wrapped with the refractory layer, and the surface of the refractory layer is entirely wrapped with the insulating layer; the busbar layer, the refractory layer, and the insulating layer are naturally stacked to form a refractory extruded rigid busbar semi-finished product; the refractory extruded rigid busbar semi-finished product is bent, and the refractory layer and the insulating layer covering the end portion are removed to expose the end portion, thus obtaining the refractory extruded rigid busbar. However, the above-mentioned busbar processing process is complex, and the processing precision of the refractory layer is difficult to control, resulting in uneven refractory layer thickness and low busbar quality. Utility Model Content

[0004] The purpose of this application is to provide a fire-resistant injection molded busbar that has easily controllable processing precision, high degree of automation, can achieve multi-dimensional molding, has a reasonable and compact structure, beautiful and elegant appearance, and has good fire resistance and insulation properties.

[0005] The refractory injection molded busbar provided in this application adopts the following technical solution:

[0006] A fire-resistant injection-molded busbar includes a processed busbar conductor, a plurality of support clips distributed along the length of the busbar conductor, and a fire-resistant insulation layer covering the busbar conductor and the support clips. The support clips are distributed on both sides of the busbar conductor, and the two ends of the busbar conductor are exposed from both ends of the fire-resistant insulation layer.

[0007] As a preferred technical solution of this application, the support clip has a U-shaped cross-section, and the three side plates abut against the upper and lower surfaces and the side surfaces of the bus conductor, respectively. The outer surfaces of the three side plates of the support clip are provided with thickness-limiting protrusions, and the top surface of the thickness-limiting protrusions is flush with the outer surface of the fire-resistant insulation layer around the fire-resistant insulation layer.

[0008] As a preferred technical solution of this application, the inner surfaces of the two opposite side plates of the support clip are provided with positioning protrusions, and the bus conductor is provided with positioning holes that are opposite to the positioning protrusions.

[0009] As a preferred technical solution of this application, the material of the support clip is the same as that of the fire-resistant insulation layer, and the thickness is 1±0.1mm.

[0010] As a preferred technical solution of this application, the busbar conductor is configured as one of copper plate, hard aluminum plate, multi-layer copper strip or multi-layer aluminum strip, and the thickness of the busbar conductor is ≥1.5mm.

[0011] As a preferred technical solution of this application, the fire-resistant insulation layer is made of thermoplastic material, mainly composed of TPU, EVA and POP composite.

[0012] As a preferred embodiment of this application, the thickness of the fire-resistant insulating layer is 1.5-2.5 mm.

[0013] As a preferred technical solution of this application, the support clips are evenly arranged along the length of the busbar conductor, and the distance between two support clips on the same side is 100mm. That is, when the length of the busbar in a certain direction is ≥100mm, support clips need to be set, and when the length of the busbar in all directions is <100mm, support clips are not set.

[0014] As a preferred technical solution of this application, when the bus conductor is stamped, a positioning hole needs to be punched at the position where the support clip is to be assembled, and the diameter of the positioning hole is 4-6mm.

[0015] In summary, this application includes at least one of the following beneficial technical effects:

[0016] 1. The fire-resistant injection-molded busbar structure of this application first forms the conductor through stamping, bending and other processes, then assembles the support clips into the designated positions of the conductor, and then performs injection molding. The final product has the advantages of simple production process, easy control of processing accuracy, high degree of automation, multi-dimensional molding capability, reasonable and compact structure, and beautiful appearance. It also has good fire resistance and insulation properties, which greatly improves the safety performance of the busbar and battery pack and provides strong protection for the safety of the whole vehicle.

[0017] 2. Multiple support clips are installed on the busbar conductor. The function of the support clips is to support the busbar conductor, prevent uneven wall thickness of the refractory insulation layer during injection molding, and improve the processing quality and precision of the busbar.

[0018] 3. The fire-resistant insulation layer gives the busbar excellent insulation, fire resistance, flame retardancy, aging resistance, impact resistance, and wear resistance.

[0019] 4. Positioning holes are provided on the busbar conductor for the installation of the support clips, which can prevent the support clips from moving and causing the injection-molded busbar dimensions to exceed the tolerance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the busbar in an embodiment of this application;

[0021] Figure 2 This is a schematic diagram of the busbar structure from another angle in an embodiment of this application;

[0022] Figure 3 This is an exploded structural diagram of the motherboard according to an embodiment of this application;

[0023] Figure 4 This is a schematic diagram of the assembly structure of the bus conductor and the support clip in an embodiment of this application;

[0024] Figure 5 This is a cross-sectional structural diagram of the position of the busbar support clip in an embodiment of this application;

[0025] In the diagram, 1 is the busbar conductor; 11 is the positioning hole; 2 is the support clip; 21 is the thickness limiting protrusion; 22 is the positioning protrusion; and 3 is the fire-resistant insulation layer. Detailed Implementation

[0026] The following is in conjunction with the appendix Figure 1-5 This application will be described in further detail below.

[0027] Example: This example proposes a refractory injection molded busbar, referring to... Figure 1-5 The busbar includes a bus conductor 1, a support clip 2, and a fire-resistant insulation layer 3. The support clip 2 is installed on the bus conductor 1. The fire-resistant insulation layer 3 is injection molded over the outside of the bus conductor 1 and also covers the support clip 2 inside, forming a fire-resistant injection molded busbar.

[0028] The bus conductor 1 is made of one of the following materials: copper plate, hard aluminum plate, multi-layer copper strip, or multi-layer aluminum strip, which has excellent conductivity. In this embodiment, copper plate is used, and the thickness of the bus conductor 1 is ≥1.5mm. The bus conductor 1 is first formed by stamping, bending, and other processes. Then, multiple support clips 2 are installed on the bus conductor 1, and finally, a fire-resistant insulating layer 3 is injected onto the surface.

[0029] The fire-resistant insulation layer 3 is made of thermoplastic material, mainly composed of TPU, EVA, and POP composite, and has excellent insulation, fire resistance, flame retardancy, aging resistance, impact resistance, and wear resistance. The thickness of the fire-resistant insulation layer 3 is 1.5-2.5mm, which ensures excellent insulation, wear resistance, and fire resistance. Both ends of the busbar conductor 1 protrude a length from both ends of the fire-resistant insulation layer 3, used to connect and conduct the busbar to other connectors. In this embodiment, the material of the support clip 2 is the same as that of the fire-resistant insulation layer 3, with a thickness of 1±0.1mm, ensuring the insulation and fire resistance of the busbar conductor 1 at the support clip 2 location.

[0030] Reference Figure 3 and 4 Support clips 2 are distributed on both sides of the busbar conductor 1. Support clips 2 on the same side are evenly distributed along the length of the busbar conductor 1, while those on both sides are staggered. The distance between two support clips 2 on the same side is 100mm. That is, support clips 2 are required when the length of the busbar conductor 1 in a certain direction is ≥100mm; when the length of the busbar conductor 1 in all directions is <100mm, support clips 2 are not required. The function of the support clips 2 is to support the busbar conductor 1 and prevent uneven wall thickness of the refractory insulation layer 2 during injection molding.

[0031] Reference Figure 4 and 5 In this embodiment, the support clip 2 has a U-shaped cross-section and is clamped onto the bus conductor 1 through an opening slot. The three side plates of the support clip 2 abut against the upper and lower surfaces and one side of the bus conductor 1, respectively. Each of the three side plates of the support clip 2 has a thickness limiting protrusion 21. The thickness limiting protrusion 21 can abut against the inner surface of the injection mold to limit the injection thickness of the fire-resistant insulation layer 3, so as to avoid the fire-resistant insulation layer 3 being too thin or uneven in thickness. In this embodiment, the top surface of the thickness limiting protrusion 21 is flush with the outer surface of the surrounding fire-resistant insulation layer 3, so that the support clip 2 and the fire-resistant insulation layer 3 are more tightly bonded, and the fire-resistant insulation layer 3 is prevented from breaking at the support clip 2.

[0032] In another embodiment of this application, to improve the firmness of the connection between the support clip 2 and the busbar conductor 1, circular positioning protrusions 22 are provided on the inner surfaces of the two opposing side plates of the support clip 2. Positioning holes 11 are provided on the busbar conductor 1 opposite to the positioning protrusions 22. The support clip 2 is secured in the positioning holes 11 by the positioning protrusions 22 to prevent the support clip 2 from detaching from the busbar conductor 1. During the stamping of the busbar conductor 1, positioning holes 11 need to be punched at the location where the support clip 2 is to be assembled. The diameter of the positioning holes is 4-6 mm, and the shape is circular. This prevents the support clip 2 from moving and causing the injection-molded busbar dimensions to exceed tolerances, meeting design requirements and not affecting performance.

[0033] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A refractory injection-molded busbar, characterized in that, It includes a bus conductor (1) that has been processed and formed, several support clips (2) distributed along the length of the bus conductor (1), and a fire-resistant insulation layer (3) covering the bus conductor (1) and the support clips (2). The support clips (2) are distributed on both sides of the bus conductor (1), and the two ends of the bus conductor (1) are exposed from the two ends of the fire-resistant insulation layer (3).

2. The refractory injection-molded busbar according to claim 1, characterized in that, The cross-section of the support clip (2) is U-shaped, and the three side plates abut against the upper and lower surfaces and the side surfaces of the bus conductor (1) respectively. The outer surfaces of the three side plates of the support clip (2) are provided with thickness-limiting protrusions (21), and the top surface of the thickness-limiting protrusions (21) is flush with the outer surface of the fire-resistant insulation layer (3) around the fire-resistant insulation layer (3).

3. A refractory injection-molded busbar according to claim 2, characterized in that, The inner surfaces of the two opposite side plates of the support clip (2) are provided with positioning protrusions (22), and the bus conductor (1) is provided with positioning holes (11) that are opposite to the positioning protrusions (22).

4. A refractory injection-molded busbar according to any one of claims 1-3, characterized in that, The material of the support clip (2) is the same as that of the fire-resistant insulation layer (3), and the thickness is 1±0.1mm.

5. A refractory injection-molded busbar according to any one of claims 1-3, characterized in that, The bus conductor (1) is made of one of copper plate, hard aluminum plate, multi-layer copper strip or multi-layer aluminum strip, and the thickness of the bus conductor (1) is ≥1.5mm.

6. A refractory injection-molded busbar according to any one of claims 1-3, characterized in that, The thickness of the fire-resistant insulating layer (3) is 1.5-2.5 mm.

7. A refractory injection-molded busbar according to any one of claims 1-3, characterized in that, The support clips (2) are evenly arranged along the length of the bus conductor (1). The distance between two support clips (2) on the same side is 100mm. That is, when the length of the busbar in a certain direction is ≥100mm, support clips (2) need to be set. When the length of the busbar in each direction is <100mm, support clips (2) are not set.

8. A refractory injection-molded busbar according to any one of claims 1-3, characterized in that, When the bus conductor (1) is stamped, a positioning hole (11) needs to be punched at the position where the support clip (2) is to be assembled. The diameter of the positioning hole (11) is 4-6mm.

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