Multi-layer composite anti-corrosion waterproof battery connecting assembly

Abstract

The utility model discloses a multi-layer composite anti-corrosion waterproof battery connecting assembly, which belongs to the field of new energy, and comprises a sleeve, a busbar, a locking bolt and a sealing ring, the busbar is arranged in the sleeve, the sealing ring is arranged between the busbar and the sleeve, and the busbar positioned in the sleeve is fixed through the locking bolt; the busbar comprises a metal layer, insulating layers and an anti-corrosion outer layer, the insulating layers are arranged on the two sides of the metal layer, the anti-corrosion outer layer is arranged on the side, away from the metal layer, of each insulating layer, and the thickness of the anti-corrosion outer layer ranges from 0.1 mm to 5 mm; the anti-corrosion outer layer is made of high polymer materials, the high polymer materials comprise rubber, PVC, PP and epoxy resin, the anti-corrosion outer layer is of a multi-layer structure, the inner layer is an epoxy resin layer, the outer layer is made of rubber, PP or PVC, the material mass ratio is 20-60 parts of the epoxy resin of the inner layer, and the material mass ratio is 40-80 parts of the rubber, PP or PVC of the outer layer, and the safety and reliability of the immersed cooling technology can be remarkably improved.

Description

Technical Field

[0001] This utility model belongs to the field of new energy technology, specifically the field of energy storage battery pack components, and more specifically a multi-layer composite anti-corrosion and waterproof battery connection assembly. Background Technology

[0002] New energy battery packs generally refer to battery systems that provide energy storage and power output for new energy vehicles such as electric vehicles and hybrid vehicles. The battery pack is one of the core components of new energy vehicles, and its performance directly affects the vehicle's range, safety, and fuel economy. With technological advancements, battery pack design and manufacturing are moving towards higher energy density, faster charging speeds, and longer lifespans.

[0003] Immersion cooling technology is a highly efficient thermal management method that achieves rapid heat transfer and dissipation by directly immersing electronic devices in a coolant. With the widespread application of immersion cooling technology, [referencing...] Figure 1 Traditional battery connection components typically use busbars with insulating layers on both sides of the metal layer. The insulating layer requires a fire rating of UL94V0. When exposed to long-term immersion in coolant, it is prone to corrosion, oxidation, and electrical failures, resulting in low system reliability and stability. Utility Model Content

[0004] The purpose of this invention is to provide a multi-layer composite anti-corrosion and waterproof battery connection assembly to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A multi-layer composite anti-corrosion and waterproof battery connection assembly.

[0007] It includes a sleeve, a busbar, a locking bolt, and a sealing ring. The busbar is installed inside the sleeve, and the sealing ring is installed between the busbar and the sleeve. The busbar located inside the sleeve is fixed by the locking bolt.

[0008] The busbar includes a metal layer, an insulating layer, and a corrosion-resistant outer layer. The insulating layer is provided on both sides of the metal layer, and the side of the insulating layer away from the metal layer is the corrosion-resistant outer layer. The thickness of the corrosion-resistant outer layer is 0.1 mm to 5 mm. The corrosion-resistant outer layer is composed of polymer materials, including rubber, PVC, PP, and epoxy resin. The corrosion-resistant outer layer has a multi-layer structure, with an inner epoxy resin layer and an outer layer of rubber, PP, or PVC. The material mass ratio is 20 to 60 parts of epoxy resin in the inner layer and 40 to 80 parts of rubber, PP, or PVC in the outer layer.

[0009] Preferably, an anti-corrosion coating is provided on both sides of the metal layer, the thickness of the anti-corrosion coating is 0.1μm to 50μm, and the anti-corrosion coating is a metal material coating or an organic material coating; when a metal material coating is used, a corrosion-resistant nickel or tin metal layer is deposited on the metal layer by electroplating or chemical plating, and then a silver or gold coating is deposited by PVD or CVD, wherein the metal composition of nickel or tin in the anti-corrosion metal coating is 90 to 99 parts, and the gold or silver component is 1 to 10 parts; when an organic material coating is used, the organic material coating is composed of a polymer material, and the polymer material is selected to be epoxy resin.

[0010] Preferably, the metal layer is composed of one or more of copper, aluminum, nickel, steel and titanium, and the thickness of the metal layer is 1 mm to 100 mm.

[0011] Preferably, the insulating layer is composed of a polymer material layer, including PVC, PP, PE, PET and PI.

[0012] Preferably, the anti-corrosion outer layer is composed of heat-shrinkable resin and rubber tubing.

[0013] Preferably, the anti-corrosion coating is a corrosion-resistant metal coating or a thin coating of polymer material.

[0014] Preferably, the corrosion-resistant metal coating is composed of nickel, tin, silver and gold.

[0015] Preferably, the polymer material thin coating is composed of epoxy resin.

[0016] The technical effects and advantages of this utility model are as follows:

[0017] 1) This utility model has high durability. The busbar, composed of a metal layer, an insulating layer, and an anti-corrosion outer layer, has extremely high corrosion resistance and durability in an immersion cooling environment, extending the service life of the components. When directly immersed in coolant, especially under high-rate discharge conditions where conductor heating increases dramatically in traditional cooling methods, it achieves a more uniform temperature distribution, prevents local overheating, and has excellent thermal management performance. Because the product has anti-corrosion, insulation, and waterproof properties that are not currently available in ordinary products, it is suitable for electrical connection scenarios in immersion liquid cooling environments in terms of waterproof performance, corrosion resistance, and insulation performance.

[0018] (2) The waterproof and insulating layers of the busbar itself, together with the sleeve and sealing ring, can effectively prevent coolant from entering the electrical parts, reduce the risk of short circuits and electrical faults, and improve the safety of the system.

[0019] (3) This utility model can be customized according to different application scenarios and needs, and is applicable to a variety of liquid cooling technology scenarios. It has a wide market application prospect and wide applicability. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the busbar structure in the background art;

[0021] Figure 2 This is a schematic diagram of the busbar structure in this utility model;

[0022] Figure 3 This is a schematic diagram of the overall structure of this utility model;

[0023] Figure 4 This is a flowchart of the present invention.

[0024] In the diagram: 1. Sleeve; 2. Busbar; 21. Metal layer; 22. Insulation layer; 23. Anti-corrosion outer layer; 24. Anti-corrosion coating; 3. Locking bolt; 4. Sealing ring. Detailed Implementation

[0025] The following will refer to the appendix in the embodiments of this utility model. Figures 2-4 The technical solutions in the embodiments of this utility model are clearly and completely described herein. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The specific embodiments described herein are merely used to explain this utility model and are not intended to limit this utility model. 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.

[0026] Example

[0027] like Figures 2-4 As shown, a multi-layer composite anti-corrosion and waterproof battery connection assembly includes a sleeve 1, a busbar 2, a locking bolt 3, and a sealing ring 4. The busbar 2 is installed inside the sleeve 1, and the sealing ring 4 is installed between the busbar 2 and the sleeve 1. The busbar 2 located inside the sleeve 1 is fixed by the locking bolt 3. An embedded sealing structure is adopted at the joint of the assembly to ensure all-round waterproof sealing during the connection process and prevent coolant from seeping into the electrical connection parts.

[0028] Busbar 2 includes a metal layer 21, an insulating layer 22, and a corrosion-resistant outer layer 23. Insulating layers 22 are provided on both sides of the metal layer 21. The side of the insulating layer 22 furthest from the metal layer 21 is the corrosion-resistant outer layer 23, which has a thickness of 0.1mm to 5mm. The corrosion-resistant outer layer 23 is composed of polymer materials, including rubber, PVC, PP, and epoxy resin. The corrosion-resistant outer layer 23 has a multi-layer structure, with an inner epoxy resin layer and an outer layer of rubber, PP, or PVC. The mass ratio of the materials is 20-60 parts epoxy resin in the inner layer and 40-80 parts rubber, PP, or PVC in the outer layer. The internal layer is a metal layer 21 with strong electrical conductivity and excellent thermal conductivity, and the external layer is covered with a corrosion-resistant and waterproof polymer material layer. The outermost layer is an insulating protective layer, effectively preventing electrical short circuits and signal interference.

[0029] Both sides of the metal layer 21 are also provided with anti-corrosion coatings 24. The thickness of the anti-corrosion coating 24 is 0.1μm to 50μm. The anti-corrosion coating 24 is a metal material coating or an organic material coating. When a metal material coating is used, a corrosion-resistant nickel or tin metal layer 21 is deposited on the metal layer 21 by electroplating or chemical plating. Then, a silver or gold coating is deposited by PVD or CVD. The metal composition of the anti-corrosion metal coating is 90 to 99 parts of nickel or tin and 1 to 10 parts of gold or silver. When an organic material coating is used, the organic material coating is composed of polymer materials. The polymer material is selected as epoxy resin. A special anti-corrosion coating 24 is applied to the metal layer 21. This coating can resist the corrosion of the coolant. It can be either a metal coating or an organic material coating.

[0030] The metal layer 21 is composed of copper, aluminum, nickel, steel and titanium, and the thickness of the metal layer 21 is 1 mm to 100 mm.

[0031] The insulating layer 22 is composed of polymer materials, including PVC, PP, PE, PET and PI.

[0032] The anti-corrosion outer layer 23 is composed of heat-shrinkable resin and rubber tubing.

[0033] The anti-corrosion coating 24 is made of corrosion-resistant metal coating or thin coating of polymer material.

[0034] The corrosion-resistant metal coating is composed of nickel, tin, silver and gold.

[0035] The polymer material thin coating is composed of epoxy resin.

[0036] A method for preparing a multilayer composite corrosion-resistant and waterproof battery connection assembly includes the following steps:

[0037] S1. Material Preparation:

[0038] Select conductive metal materials, select polymer anti-corrosion materials or corrosion-resistant metal layer 21, and prepare insulating layer 22 materials.

[0039] S2. Metal layer forming: The metal material is processed into the required shape of the connector, and the metal surface is cleaned. The metal material processing technology is one or more of the following: casting, profile extrusion molding, 3D printing, powder metallurgy, stamping, laser cutting, machining, welding, riveting, etc.

[0040] S3. Apply anti-corrosion coating: uniformly deposit anti-corrosion coating 24 on metal layer 21, and cure the coating. The anti-corrosion coating 24 is processed by one or more of the following processes: PVD, CVD, electroplating, chemical plating, electrophoresis, spray painting, powder coating, dip coating, ultrasonic powder deposition, etc.

[0041] S4. Insulation layer coating: Apply insulating material to the metal anti-corrosion layer, and cure the insulation layer 22. The processing technology of the insulation layer 22 is one or more of the following processes: painting, powder coating, dip coating, wrapping plastic tape, injection molding, and nesting of insulating plastic shell.

[0042] S5. High-polymer anti-corrosion outer layer, covering high-polymer material to ensure overall sealing; the process of high-polymer anti-corrosion outer layer 23 is one or more of the following processes: powder spraying, dip coating, wrapping plastic tape, injection molding, and insulated plastic shell nesting.

[0043] S6. Embedded sealing design, with an embedded sealing structure to ensure the sealing performance of the part;

[0044] S7. Product testing and verification: corrosion resistance test, waterproof performance test, and electrical performance test; the waterproof test adopts the IP67 test standard, the corrosion resistance test adopts the salt spray test standard, and the electrical performance meets the insulation requirements of no less than 3000VDC in the current electrical systems of new energy vehicles.

[0045] In summary, this utility model has high durability, excellent thermal management performance, and reliable waterproofing.

[0046] Example 1

[0047] Metal layer 21 is pure copper; anti-corrosion coating 24 is selected from 99 parts of electroplated nickel and 1 part of PVD deposited silver; insulation layer 22 is powder-coated epoxy resin; anti-corrosion outer layer 23 is 20 parts of powder-impregnated epoxy resin and outermost layer is 80 parts of PVC-impregnated.

[0048] Comparative Example 1

[0049] The metal layer 21 is pure copper; the insulating layer 22 is powder-coated epoxy resin.

[0050] Comparative Example 1 had no anti-corrosion coating 24, and its surface was severely corroded after the salt spray test; the insulation layer 22 only covered a portion of the area, and in immersion cooling, the metal layer 21 was exposed to the coolant, and the coolant directly contacted the electrical connection joints, posing a high risk.

[0051] In Example 1, the anti-corrosion layer completely covers the metal layer 21, and no corrosion was observed on the surface after salt spray testing. The insulation layer 22 and the anti-corrosion outer layer 23 cover the entire area except for the joint. The joint uses an embedded sealing structure for connection. After locking, the sealing rubber ring in the embedded sealing structure is compressed and deformed, isolating the joint from the coolant. The coolant cannot come into contact with the electrical connection joint. At the same time, since the metal layer 21 is completely covered by the anti-corrosion metal layer 21, the coolant vapor that enters the space of the electrical connection joint during operation will not affect the electrical performance of the joint.

[0052] Finally, it should be noted that the above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 multi-layer composite anti-corrosion and waterproof battery connection assembly, characterized in that: Includes a sleeve (1), a manifold (2), a locking bolt (3), and a sealing ring (4). The manifold (2) is installed inside the sleeve (1), and the sealing ring (4) is installed between the manifold (2) and the sleeve (1). The manifold (2) located inside the sleeve (1) is fixed by the locking bolt (3). The busbar (2) includes a metal layer (21), an insulating layer (22), and an anti-corrosion outer layer (23). The insulating layer (22) is provided on both sides of the metal layer (21). The side of the insulating layer (22) away from the metal layer (21) is the anti-corrosion outer layer (23). The thickness of the anti-corrosion outer layer (23) is 0.1mm to 5mm. The anti-corrosion outer layer (23) is composed of polymer materials, including rubber, PVC, PP, and epoxy resin. The anti-corrosion outer layer (23) has a multi-layer structure, with an inner epoxy resin layer and an outer rubber, PP, or PVC layer. The material mass ratio is 20 to 60 parts of epoxy resin in the inner layer and 40 to 80 parts of rubber, PP, or PVC in the outer layer.

2. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 1, characterized in that: The metal layer (21) is provided with anti-corrosion coatings (24) on both sides. The thickness of the anti-corrosion coatings (24) is 0.1μm~50μm. The anti-corrosion coatings (24) are metal material coatings or organic material coatings. When a metal material coating is used, a corrosion-resistant nickel or tin metal layer (21) is deposited on the metal layer (21) by electroplating or chemical plating, and then a silver or gold coating is deposited by PVD or CVD. The metal composition of the anti-corrosion metal coating is 90 to 99 parts of nickel or tin and 1 to 10 parts of gold or silver. When an organic material coating is used, wherein the organic material coating is composed of a polymer material, the polymer material is selected to be epoxy resin.

3. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 2, characterized in that: The anti-corrosion coating (24) is a corrosion-resistant metal coating or a thin coating of polymer material.

4. The multi-layer composite anti-corrosion and waterproof battery connection assembly according to claim 3, characterized in that: The polymer material thin coating is composed of epoxy resin.

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