Busbar for new energy automobile

Abstract

The utility model discloses a busbar for a new energy automobile, which comprises a conductor inner core, the conductor inner core is formed by superposing a plurality of layers of copper foils, the outer surface of the conductor inner core is sequentially coated with a mica tape and a polytetrafluoroethylene layer, and an integrated structure is formed through hot pressing and high-temperature sintering treatment. According to the utility model, the bending performance and the structural stability can be greatly improved while the conductive performance is ensured.

Description

TECHNICAL FIELD

[0001] The utility model relates to busbar technical field especially is related to a busbar for new energy automobile. BACKGROUND

[0002] As a key power transmission component in new energy vehicles, the performance of the busbar directly affects the stability and reliability of the vehicle electrical system. With the rapid development of the new energy vehicle industry, higher requirements are placed on the design and manufacture of busbars. Especially in the aspect of special-shaped processing, traditional busbars are difficult to meet the needs of complex shapes, limiting their application in high-performance and lightweight design. Therefore, developing a new type of busbar that can adapt to various bending needs has become an important topic in the industry.

[0003] Currently, to solve the limitations of busbars in bending processing, the industry usually adopts the following methods: first, using pure copper material to make busbars, optimizing the processing technology to improve the bending performance; second, by adding auxiliary support structures such as metal skeletons or reinforcing ribs to improve the overall rigidity of the busbar; third, using composite materials to replace traditional copper bars, such as combining copper with aluminum or other alloy materials, trying to balance strength and flexibility.

[0004] However, the above methods still have obvious defects, especially in the special-shaped processing process, traditional busbars are prone to cracking or deformation, making it difficult to meet complex bending needs. In addition, pure copper structure busbars will lose elasticity after multiple bending due to hardening, resulting in a decrease in processing precision. Therefore, there is an urgent need for a new type of busbar structure that can significantly improve its bending performance and structural stability while ensuring electrical conductivity. SUMMARY

[0005] The present application provides a busbar for new energy vehicles that can significantly improve its bending performance and structural stability while ensuring electrical conductivity.

[0006] The present application provides a busbar for new energy vehicles that adopts the following technical solution:

[0007] A busbar for new energy vehicles, comprising a conductor core, the conductor core is formed by stacking multiple layers of copper foil, the outer surface of the conductor core is covered with mica tape and polytetrafluoroethylene layer in turn, and the conductor core is formed into an integral structure through hot pressing and high-temperature sintering treatment.

[0008] By adopting the technical scheme, the busbar for new energy vehicles is formed by the conductor inner core formed by the multiple layers of copper foils, replaces the traditional pure copper structure, is more flexible, meets the complex bending processing requirement, and is suitable for the manufacturing of special-shaped busbars.

[0009] Preferably, the total thickness of the conductor inner core is 2.5 mm, and the copper foils inside are divided into 5 layers, each layer having a thickness of 0.5 mm.

[0010] By adopting the technical scheme, the conductor inner core formed by the multiple layers of copper foils has better flexibility, meets the special-shaped processing requirement, and especially meets the bending processing requirement. The total thickness of the conductor inner core is set to 2.5 mm, and the copper foils inside are divided into 5 layers, each layer having a thickness of 0.5 mm. This design makes the stress distribution between the copper foils more uniform, thereby ensuring the overall structural strength and further improving the flexibility and processing performance of the busbar.

[0011] Preferably, the middle section of the conductor inner core fixes the copper foils in each layer in a wrapping manner, so as to ensure the close connection between the layers.

[0012] By adopting the technical scheme, the conductor inner core of the busbar is formed by the multiple layers of copper foils, and the copper foils in the middle section are fixed in a wrapping manner, so as to ensure the close connection between the layers. This manner effectively enhances the overall structural stability of the conductor inner core, especially in the special-shaped processing and bending process, can reduce the risk of separation between the layers, and improves the reliability of the busbar in the manufacturing of complex shapes.

[0013] Preferably, the two ends of the copper foil are fixed in a press welding manner, thereby improving the stability of the multiple layers of copper foils.

[0014] By adopting the technical scheme, the two ends of the multiple layers of copper foils are fixed in a press welding manner, which can significantly improve the overall stability of the laminated structure, and effectively prevent the copper foils from loosening or separating during the processing or use.

[0015] Preferably, the thickness of the mica tape is 0.1 mm, which completely wraps the outer surface of the conductor inner core to form a tightly fitted inner protective structure.

[0016] By adopting the technical scheme, in use, the thickness of the mica tape is 0.1 mm and is completely wrapped on the outer surface of the conductor inner core, so that a closely fitted inner protection structure is formed, the electrical insulation performance and heat resistance of the conductor inner core are effectively improved, and the conductor inner core is prevented from being damaged externally in the processing process.

[0017] Preferably, the thickness of the polytetrafluoroethylene layer is 0.1 mm, and the polytetrafluoroethylene layer completely covers the outer surface of the mica tape to form an outer protection structure.

[0018] By adopting the technical scheme, in use, the outer protection structure of the busbar for new energy vehicles is formed by the polytetrafluoroethylene layer with a thickness of 0.1 mm completely covering the outer surface of the mica tape. The polytetrafluoroethylene layer has excellent high-temperature resistance, corrosion resistance and insulation performance, and can effectively protect the conductor inner core and the mica tape inside, and improve the overall durability and safety of the busbar.

[0019] In summary, the present application has the following beneficial effects:

[0020] 1. The busbar for new energy vehicles is designed, the conductor inner core is formed by a plurality of copper foils stacked, is softer than a pure copper structure, can meet the bending demand of a complex shape, and effectively solves the problem that a traditional busbar is easily broken or deformed in special-shaped processing.

[0021] 2. The busbar for new energy vehicles is designed, the conductor inner core, the mica tape and the polytetrafluoroethylene layer form an integrated structure through hot pressing and high-temperature sintering treatment, the overall structural stability and durability are improved, and the busbar has good insulation and heat resistance.

[0022] 3. The busbar for new energy vehicles is designed, the copper foils are fixed through wrapping and pressure welding, the close connection between the stacked layers is ensured, the stability of the busbar after being bent for many times is enhanced, and the decline of processing precision caused by hardening is avoided. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 The structure schematic view of the embodiment is shown in the figure.

[0024] The reference signs are explained as follows: 1, conductor inner core; 11, copper foil; 2, mica tape; 3, polytetrafluoroethylene layer. DETAILED DESCRIPTION

[0025] The utility model will be further described in detail below in combination with the drawings. Same parts are denoted by same reference signs in the drawings. It should be noted that the words "front", "back", "left", "right", "up", "down", "bottom surface" and "top surface" in the following description refer to the directions in the drawings, and the words "inner" and "outer" refer to the directions towards or away from the geometric center of a specific part.

[0026] This utility model discloses a busbar for new energy vehicles, such as Figure 1 As shown, the busbar includes a conductor core 1, a mica tape 2, and a polytetrafluoroethylene (PTFE) layer 3. The conductor core 1 is formed by stacking multiple layers of copper foil 11. The mica tape 2 completely wraps the outer surface of the conductor core 1, and the PTFE layer 3 covers the outer surface of the mica tape 2. The busbar is formed into an integrated structure through hot pressing and high-temperature sintering, which improves the bending performance and structural stability of the busbar. This is because the stacked structure of multiple layers of copper foil 11 can effectively disperse stress, and the double-layer protective structure of the mica tape 2 and the PTFE layer 3 further enhances the overall strength and durability.

[0027] Specifically, the conductor core 1 comprises multiple layers of copper foil 11. The total thickness of the conductor core 1 is 2.5 mm, and the copper foil 11 inside is divided into 5 layers, each with a thickness of 0.5 mm. The layers of copper foil 11 are fixed together by wrapping, and the wrapping material can be high-strength fiber tape or metal wire to ensure a tight connection between the layers and prevent relative slippage between the copper foils 11. In addition, the two ends of the copper foil 11 are fixed by pressure welding. The pressure welding process can be resistance welding, ultrasonic welding, or polymer diffusion welding. Both methods can achieve a firm connection without damaging the structure of the copper foil 11.

[0028] Mica tape 2, serving as the inner protective structure, has a thickness of 0.1 mm and completely wraps around the outer surface of the conductor core 1. The mica tape 2 can be made of natural mica or synthetic mica, both of which possess excellent heat resistance and insulation properties. The mica tape 2 can be wound in a single layer or multiple overlapping layers, the specific method to be selected based on the actual application scenario.

[0029] The PTFE layer 3, serving as the outer protective structure, also has a thickness of 0.1 mm and completely covers the outer surface of the mica tape 2. The material properties of the PTFE layer 3 give it excellent corrosion resistance and wear resistance, effectively resisting environmental erosion. The PTFE layer 3 can be formed by compression molding or extrusion molding; both methods ensure a tight bond with the mica tape 2.

[0030] Through hot pressing and high-temperature sintering, the conductor core 1, mica tape 2, and polytetrafluoroethylene layer 3 are formed into an integrated structure. The temperature range of the hot pressing process is typically set between 300℃ and 400℃, and the pressure range is between 10MPa and 20MPa. Specific parameters need to be optimized according to the material properties. High-temperature sintering further enhances the bonding strength between the layers, ensuring the long-term stability of the overall structure.

[0031] Working principle: the utility model discloses a new energy automobile busbar, through adopting multilayer copper foil 11 superposition structure as the conductor inner core 1, the bending performance and structural stability of busbar have been improved significantly. The double-layer protection structure of mica tape 2 and polytetrafluoroethylene layer 3 not only enhances the heat resistance and insulation performance of busbar, but also effectively prevents the erosion of external environment to the conductor inner core 1. The combination application of wrapping and pressure welding process ensures the close connection between multilayer copper foil 11, thereby avoiding the delamination or loosening phenomenon in the complex bending process.

[0032] The above are preferred embodiments of the present application, and do not limit the protection scope of the present application, therefore: all equivalent changes made according to the structure, shape, principle of the present application should be covered within the protection scope of the present application.

Claims

1. A busbar for new energy vehicles, characterized in that: It includes a conductor core (1), which is formed by stacking multiple layers of copper foil (11). The outer surface of the conductor core (1) is sequentially covered with mica tape (2) and polytetrafluoroethylene layer (3), and is formed into an integral structure by hot pressing and high-temperature sintering.

2. The busbar for new energy vehicles according to claim 1, characterized in that: The conductor core (1) has a total thickness of 2.5 mm, and the copper foil (11) inside it is divided into 5 layers, each with a thickness of 0.5 mm.

3. The busbar for new energy vehicles according to claim 1, characterized in that: The middle section of the conductor core (1) is fixed with each layer of copper foil (11) by wrapping to ensure a tight connection between the layers.

4. A busbar for new energy vehicles according to claim 1, characterized in that: The two ends of the copper foil (11) are fixed by pressure welding, thereby improving the stability of the multilayer copper foil (11).

5. A busbar for new energy vehicles according to claim 1, characterized in that: The mica tape (2) has a thickness of 0.1 mm and completely wraps around the outer surface of the conductor core (1), forming a tightly fitted inner protective structure.

6. A busbar for new energy vehicles according to claim 1, characterized in that: The polytetrafluoroethylene layer (3) has a thickness of 0.1 mm and completely covers the outer surface of the mica tape (2), forming an outer protective structure.

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