Flexible and bendable composite busbar device

Abstract

The utility model relates to the field of power transmission, and discloses a flexible and bendable composite busbar device, which comprises a positive plate, a first middle buffer layer fixedly connected to the surface of the positive plate, a lower buffer layer fixedly connected to the surface of the positive plate, a lower insulating layer fixedly connected to the surface of the lower buffer layer, and a second middle buffer layer fixedly connected to the surface of the lower insulating layer. The surface of the lower insulation layer is fixedly connected with a lower protection layer, the surface of the first middle buffer layer is fixedly connected with a first middle insulation layer, the surface of the first middle insulation layer is fixedly connected with a second middle insulation layer, and the surface of the second middle insulation layer is fixedly connected with a second middle buffer layer. According to the utility model, the positive plate and the negative plate adopt the upper protection layer and the lower protection layer made of the aluminum alloy material and the epoxy powder coating material, so that the surface strength can be enhanced, the conductivity, the mechanical strength and the flexibility of the composite busbar are balanced, and the problem that the composite busbar cannot be used in complex electronic equipment is solved.

Description

Technical Field

[0001] This utility model relates to the field of power transmission, and in particular to a flexible and bendable composite busbar device. Background Technology

[0002] Compared to traditional, bulky, time-consuming, and cumbersome wiring methods, composite busbars offer modern, easy-to-design, quick-to-install, and clearly structured power distribution systems. They are high-power modular connection components characterized by repeatable electrical performance, low impedance, interference immunity, high reliability, space saving, and simple and quick assembly.

[0003] A search revealed that, according to publication number CN211556361U, this utility model discloses a composite busbar, comprising a first DC busbar assembly, a second DC busbar assembly, and an AC busbar assembly. The first DC busbar assembly includes a first overlapping area; the second DC busbar assembly includes a second overlapping area overlapping the first overlapping area and a third overlapping area connected to the second overlapping area; the AC busbar assembly includes a fourth overlapping area overlapping the third overlapping area and an installation area connected to the fourth overlapping area. The first overlapping area has a first connecting hole and a first clearance area; the second overlapping area has a second clearance hole and a third clearance hole; the third overlapping area has a fourth clearance hole and a second connecting hole; the fourth overlapping area has a fifth clearance hole in the area overlapping with the second connecting hole; and the fourth overlapping area has a third connecting hole in the area overlapping with the fourth clearance hole. The installation area also has a sixth clearance hole and a fourth connecting hole. This utility model solves the technical problem that existing composite busbars cannot accommodate multiple IGBTs.

[0004] However, traditional composite busbars are usually rigid, making it difficult to adapt to complex shapes and space constraints, and their reliability decreases under vibration and shock environments. Currently, in order to solve the limitations of rigid composite busbars, some research focuses on improving busbar materials to enhance their flexibility. However, these methods often sacrifice the conductivity or mechanical strength of the busbar. Existing flexible composite busbar solutions are difficult to balance between conductivity, mechanical strength and flexibility, which limits their application in complex electronic devices. Utility Model Content

[0005] To overcome the above shortcomings, this utility model provides a flexible and bendable composite busbar device, which aims to improve the problem of the difficulty in achieving a balance between conductivity, mechanical strength and flexibility in flexible composite busbar solutions.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a flexible and bendable composite busbar device, comprising a positive electrode plate, a first middle buffer layer fixedly connected to the surface of the positive electrode plate, a lower buffer layer fixedly connected to the surface of the positive electrode plate, a lower insulating layer fixedly connected to the surface of the lower buffer layer, a lower protective layer fixedly connected to the surface of the lower insulating layer, a first middle insulating layer fixedly connected to the surface of the first middle buffer layer, a second middle insulating layer fixedly connected to the surface of the first middle insulating layer, a second middle buffer layer fixedly connected to the surface of the second middle insulating layer, a negative electrode plate fixedly connected to the surface of the second middle buffer layer, an upper buffer layer fixedly connected to the surface of the negative electrode plate, an upper insulating layer fixedly connected to the surface of the upper buffer layer, an upper protective layer fixedly connected to the surface of the upper insulating layer, and a quick-release assembly provided on the surface of the upper protective layer.

[0007] The above technical solution isolates the positive and negative plates by using a multi-layered insulation layer consisting of a first middle insulation layer, a second middle insulation layer, a lower insulation layer, and an upper insulation layer. This reduces the risk of electrical short circuits, improves the insulation performance of the composite busbar device, optimizes current distribution, reduces power loss during transmission, and enhances conductivity. The first middle buffer layer, the second middle buffer layer, the lower buffer layer, and the upper buffer layer improve the busbar's buffering and shock absorption capabilities, while the lower and upper protective layers reduce the risk of corrosion to the internal structure of the busbar.

[0008] Preferably, the quick-release assembly includes two fixing plates, both of which are fixedly connected to the upper protective layer. An outer cover is fixedly connected to the surface of the upper protective layer. Control rods are slidably connected inside the two fixing plates. A locking block is fixedly connected to an adjacent side of the two control rods. A fixing block is provided on the surface of the two locking blocks, and a heat sink is fixedly connected to the surface of the fixing block.

[0009] Through the above technical solution: the fixed plate is fixedly connected to the upper protective layer, providing an installation base for the radiator. The cooperation between the locking block and the fixing block can firmly install the radiator on the busbar device, ensuring the heat conduction performance between the radiator and the busbar. The outer cover fixes the movement of the locking block, so that the locking block will not deviate when it moves, and the fixing block will not shake after being limited by the locking block, thus improving the stability of the overall structure.

[0010] Preferably, the positive electrode plate is made of aluminum alloy, and the negative electrode plate is made of aluminum alloy.

[0011] Through the above technical solutions: aluminum alloy has high conductivity, which can reduce the resistance of the busbar; aluminum alloy can withstand large currents without generating excessive heat, which allows the composite busbar device to operate stably in high-power electrical systems; aluminum alloy has a relatively low density, which can reduce the overall weight of the composite busbar device; aluminum alloy has flexibility and ductility, which allows the busbar device to be bent; when the device needs to be bent or adapted to different installation spaces, the positive and negative plates of aluminum alloy can deform accordingly without breaking or being damaged.

[0012] Preferably, the first middle insulating layer is made of ethylene propylene rubber, the second middle insulating layer is made of ethylene propylene rubber, the upper insulating layer is made of ethylene propylene rubber, and the lower insulating layer is made of ethylene propylene rubber.

[0013] Through the above technical solutions: Ethylene propylene rubber has excellent insulation properties, can withstand high voltages without breakdown, and can effectively prevent leakage between the positive and negative plates and between the busbar and the external environment, ensuring the safe operation of electrical equipment. The insulation performance of ethylene propylene rubber is stable, reducing the risk of insulation performance degradation due to temperature changes. Ethylene propylene rubber is flexible and can adapt to the bending requirements of composite busbar devices. During the bending process of the busbar, the insulation layer of ethylene propylene rubber will not crack or break, ensuring the integrity and insulation effect of the insulation layer, enabling the busbar to work in different installation environments. Even when bent for a long time, ethylene propylene rubber can maintain its shape and performance and will not lose its insulation performance or undergo permanent deformation due to long-term deformation.

[0014] Preferably, the first middle buffer layer is made of silicone, the second middle buffer layer is made of silicone, the upper buffer layer is made of silicone, and the lower buffer layer is made of silicone.

[0015] Through the above technical solution, the silicone buffer layer and the ethylene propylene rubber insulation layer can be combined to form a multi-layer insulation protection. The silicone can adapt to the bendability of the composite busbar device. During the bending process of the busbar, the silicone buffer layer can deform along with the busbar without breaking or delaminating. The silicone can absorb and disperse external vibrations and impacts, protecting the conductive layer from damage.

[0016] Preferably, the upper protective layer is an epoxy powder coating, and the lower protective layer is an epoxy powder coating.

[0017] Through the above technical solutions: the epoxy powder coating has corrosion resistance and can resist various types of erosion. The epoxy powder coating also has moisture and water resistance, which can prevent water from contacting the internal structure of the busbar. In addition, the epoxy powder coating has high hardness and can resist scratches and collisions from external objects.

[0018] Preferably, the outer cover is slidably connected to the fixing block, and the outer cover is slidably connected to the control rod.

[0019] Through the above technical solution: when installing the radiator, the sliding connection between the outer cover and the fixing block and control rod makes the installation process smoother, shortens the installation time, and improves work efficiency. The sliding connection between the outer cover and the fixing block and control rod provides positioning and guiding functions for the components. When installing the radiator, the sliding track of the outer cover ensures that the control rod and the fixing block can be aligned.

[0020] Preferably, springs are fixedly connected to opposite sides of the two blocks, and both springs are fixedly connected to the two fixing plates.

[0021] Through the above technical solution: the elastic force of the spring keeps the locking block always exerting a force towards the fixed block. When the fixed block is inserted between the two locking blocks, the spring pushes the locking block to reset and lock the fixed block.

[0022] This utility model has the following beneficial effects:

[0023] 1. In this utility model, the positive and negative plates are made of aluminum alloy to ensure efficient power transmission. The upper and lower protective layers of epoxy powder coating can enhance surface strength. The aluminum alloy has a certain degree of flexibility while ensuring conductivity, thereby ensuring that the composite busbar can adapt to the compact and irregular spatial layout inside complex electronic devices. This allows the composite busbar to achieve a balance between conductivity, mechanical strength and flexibility, solving the problem that composite busbars cannot be used in complex electronic devices.

[0024] 2. In this utility model, pulling the control lever causes the locking block to move to both sides against the spring force, disengaging it from the fixing block, thus removing the radiator. The fixing block is then aligned with the locking block and inserted into the outer cover. The fixing block presses against the locking block, causing it to compress the spring and move to both sides. Once the fixing block is fully inside the outer cover, the spring force causes the locking block to insert into the fixing block, enabling the radiator to be quickly disassembled and assembled as needed, thus solving the problem of the radiator not being able to be quickly disassembled and assembled as needed. Attached Figure Description

[0025] Figure 1 This is a three-dimensional schematic diagram of a flexible and bendable composite busbar device proposed in this utility model;

[0026] Figure 2 This is a schematic diagram of the lower protective layer of a flexible and bendable composite busbar device proposed in this utility model;

[0027] Figure 3 This is a schematic diagram of the positive electrode plate of a flexible and bendable composite busbar device proposed in this utility model;

[0028] Figure 4This is a schematic diagram of a radiator for a flexible and bendable composite busbar device proposed in this utility model.

[0029] Figure 5 This is a schematic diagram of the locking block of a flexible and bendable composite busbar device proposed in this utility model;

[0030] Figure 6 This is a schematic diagram of the fixing block of a flexible and bendable composite busbar device proposed in this utility model.

[0031] Legend:

[0032] 1. Positive electrode plate; 2. Negative electrode plate; 3. First middle insulating layer; 4. Second middle insulating layer; 5. First middle buffer layer; 6. Second middle buffer layer; 7. Lower buffer layer; 8. Upper buffer layer; 9. Lower insulating layer; 10. Upper insulating layer; 11. Lower protective layer; 12. Upper protective layer; 13. Fixing block; 14. Fixing plate; 15. Control lever; 16. Spring; 17. Locking block; 18. Heat sink; 19. Outer cover. Detailed Implementation

[0033] The technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the 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.

[0034] Reference Figures 1-3 An embodiment of this utility model provides a flexible and bendable composite busbar device, including a positive electrode plate 1, a first middle buffer layer 5 fixedly connected to the surface of the positive electrode plate 1, a lower buffer layer 7 fixedly connected to the surface of the positive electrode plate 1, a lower insulating layer 9 fixedly connected to the surface of the lower buffer layer 7, a lower protective layer 11 fixedly connected to the surface of the lower insulating layer 9, a first middle insulating layer 3 fixedly connected to the surface of the first middle buffer layer 5, a second middle insulating layer 4 fixedly connected to the surface of the first middle insulating layer 3, a second middle buffer layer 6 fixedly connected to the surface of the second middle insulating layer 4, a negative electrode plate 2 fixedly connected to the surface of the second middle buffer layer 6, an upper buffer layer 8 fixedly connected to the surface of the negative electrode plate 2, an upper insulating layer 10 fixedly connected to the surface of the upper buffer layer 8, an upper protective layer 12 fixedly connected to the surface of the upper insulating layer 10, and a quick-release assembly provided on the surface of the upper protective layer 12;

[0035] Specifically, the first middle buffer layer 5, the second middle buffer layer 6, the upper buffer layer 8, and the lower buffer layer 7 are all made of silicone. The elasticity of silicone can buffer stress and prevent damage to the internal structure when the device is subjected to vibration, impact, or bending. The first middle insulation layer 3, the second middle insulation layer 4, the upper insulation layer 10, and the lower insulation layer 9 are made of ethylene propylene rubber. Ethylene propylene rubber has high insulation strength and flexibility, which can not only prevent leakage and short circuit, but also allow the insulation layer to deform with the busbar during bending without cracking or breaking, ensuring that the insulation remains unchanged. The upper protective layer 12 and the lower protective layer 11 are epoxy powder coatings, which have anti-corrosion, moisture-proof, waterproof, and wear-resistant properties.

[0036] Reference Figures 4-6 The quick-release assembly includes two fixing plates 14, both of which are fixedly connected to the upper protective layer 12. An outer cover 19 is fixedly connected to the surface of the upper protective layer 12. Control rods 15 are slidably connected inside the two fixing plates 14. A locking block 17 is fixedly connected to the adjacent side of the two control rods 15. A fixing block 13 is provided on the surface of the two locking blocks 17. A heat sink 18 is fixedly connected to the surface of the fixing block 13.

[0037] Specifically, the two fixing plates 14 are fixed to the upper protective layer 12 using a combination of high-strength adhesive and mechanical fastening. In the bonding process, an adhesive compatible with the epoxy powder coating of the upper protective layer 12 is selected to ensure that the fixing plates 14 and the upper protective layer 12 are tightly bonded, enhancing the strength of the connection and preventing loosening during long-term use. At the same time, the fixing plates 14 are further reinforced by pre-embedded screws or rivets to ensure that they are stably fixed. The outer cover 19 fixed to the surface of the upper protective layer 12 has a track inside, so that the control rod 15 and the fixing block 13 do not jam or shift during the sliding process.

[0038] Reference Figure 3 Positive electrode plate 1 is made of aluminum alloy, and negative electrode plate 2 is made of aluminum alloy.

[0039] Specifically, the positive electrode plate 1 and the negative electrode plate 2 are made of aluminum alloy. Aluminum alloy has high conductivity and low resistivity, which can reduce resistance loss during current transmission. When the composite busbar device is in operation, it can reduce energy waste caused by resistance heating. Aluminum alloy has low raw material cost and simple processing technology, which can reduce the manufacturing cost of the composite busbar device.

[0040] Reference Figure 3 The first middle insulation layer 3 is made of ethylene propylene rubber, the second middle insulation layer 4 is made of ethylene propylene rubber, the upper insulation layer 10 is made of ethylene propylene rubber, and the lower insulation layer 9 is made of ethylene propylene rubber.

[0041] Specifically, the first middle insulation layer 3, the second middle insulation layer 4, the upper insulation layer 10, and the lower insulation layer 9 are made of ethylene propylene rubber. Ethylene propylene rubber has high insulation, flexibility, and elasticity. When the busbar needs to be bent into various shapes to adapt to complex spatial layouts during installation, the ethylene propylene rubber insulation layer can bend along with the busbar without breaking, delaminating, or reducing insulation performance.

[0042] Reference Figure 3 The first middle buffer layer 5 is made of silicone, the second middle buffer layer 6 is made of silicone, the upper buffer layer 8 is made of silicone, and the lower buffer layer 7 is made of silicone.

[0043] Specifically, the first middle buffer layer 5, the second middle buffer layer 6, the upper buffer layer 8, and the lower buffer layer 7 are made of silicone. Silicone is elastic, which reduces the possibility of damage to key components of the device due to external forces.

[0044] Reference Figure 3 The upper protective layer 12 is an epoxy powder coating, and the lower protective layer 11 is an epoxy powder coating.

[0045] Specifically, the upper protective layer 12 and the lower protective layer 11 are coated with epoxy powder. The epoxy powder coating has anti-corrosion properties, reducing failures caused by corrosion. The epoxy powder coating also has hardness, wear resistance and flexibility, which prevents the coating from cracking or peeling when the composite busbar device is bent.

[0046] Reference Figures 4-6 The outer cover 19 is slidably connected to the fixed block 13, and the outer cover 19 is slidably connected to the control rod 15;

[0047] Specifically, the outer cover 19 has two sliding grooves inside. The moving groove matches the fixed block 13 and the control rod 15 to ensure that the fixed block 13 and the control rod 15 can slide stably. At the same time, the surface of the sliding groove is finely polished to reduce the friction when the fixed block 13 and the control rod 15 slide.

[0048] Reference Figures 4-6 Two springs 16 are fixedly connected to opposite sides of the two locking blocks 17, and the two springs 16 are fixedly connected to the two fixing plates 14.

[0049] Specifically, one end of the spring 16 is welded to the locking block 17, and the other end is hung on the pre-set hanging hole of the fixing plate 14 through a hook structure. The size of the hook and the hanging hole are precisely matched. The spring 16 is made of high carbon steel and has undergone special quenching and tempering treatment, which gives it a good elastic coefficient. Under normal working conditions, the spring 16 is always in a slightly stretched pre-tightened state. This pre-tightening force makes the locking block 17 always tend to move closer to the fixing block 13. When the fixing block 13 is inserted, the locking block 17 can tightly lock the fixing block 13 under the action of the spring 16.

[0050] Working principle: The positive plate 1 and negative plate 2 of this composite busbar device are made of aluminum alloy. Aluminum alloy has high electrical conductivity, which can provide a low-resistance path for current and ensure efficient transmission of electrical energy in the busbar. The first middle buffer layer 5, the second middle buffer layer 6, the upper buffer layer 8 and the lower buffer layer 7 are all made of silicone. Silicone has a certain toughness and strength, which can enhance the overall mechanical strength of the composite busbar to a certain extent. At the same time, the first middle insulation layer 3, the second middle insulation layer 4, the upper insulation layer 10 and the lower insulation layer 9 are made of ethylene propylene rubber. Ethylene propylene rubber not only has good insulation performance, but also has good mechanical properties, which further improves the strength of the composite busbar. The upper protective layer 12 and the lower protective layer 11 are epoxy powder coatings. Epoxy powder coatings have good hardness and wear resistance, which can enhance the surface strength of the composite busbar, protect the internal structure from external mechanical damage, thereby improving the mechanical strength of the entire composite busbar and enabling it to withstand certain external forces.

[0051] Aluminum alloy, while possessing high conductivity, also exhibits a certain degree of flexibility, providing a foundation for the overall bendability of the composite busbar. The silicone buffer layer has good elasticity and flexibility, enabling it to deform when the busbar is bent, absorbing bending stress and preventing damage to the internal structure due to stress concentration. The ethylene propylene rubber insulation layer also has good flexibility, working in synergy with the buffer layer to ensure that the layers of the composite busbar can deform in a coordinated manner during bending, guaranteeing the overall flexibility of the busbar and allowing it to adapt to the compact and irregular spatial layout inside complex electronic devices.

[0052] When the radiator 18 needs to be disassembled, pull the two control levers 15 outwards. The movement of the control levers 15 will cause the locking blocks 17 to move to both sides against the elastic force of the spring 16, so that the locking blocks 17 are disengaged from the fixing blocks 13. At this time, the radiator 18 can be removed from the composite busbar device. When installing the radiator 18, first align the fixing blocks 13 with the position between the two locking blocks 17, and insert the two locking blocks 17 into the outer cover 19. As the fixing blocks 13 go deeper, they will squeeze the locking blocks 17, causing the locking blocks 17 to move to both sides and compress the spring 16. When the fixing blocks 13 are completely inside the outer cover 19, under the elastic force of the spring 16, the locking blocks 17 will be inserted into the fixing blocks 13, thereby fixing the radiator 18 to the surface of the upper protective layer 12 of the composite busbar. This realizes the quick installation and removal of the radiator 18 according to the usage situation, and solves the problem that the busbar radiator 18 cannot be quickly installed and removed according to the usage situation.

[0053] Finally, 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. 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 flexible and bendable composite busbar device, comprising a positive electrode plate (1), characterized in that: The positive electrode plate (1) is fixedly connected to a first middle buffer layer (5), the positive electrode plate (1) is fixedly connected to a lower buffer layer (7), the lower buffer layer (7) is fixedly connected to a lower insulating layer (9), the lower insulating layer (9) is fixedly connected to a lower protective layer (11), the first middle buffer layer (5) is fixedly connected to a first middle insulating layer (3), the first middle insulating layer (3) is fixedly connected to a second middle insulating layer (4), the second middle insulating layer (4) is fixedly connected to a second middle buffer layer (6), the second middle buffer layer (6) is fixedly connected to a negative electrode plate (2), the negative electrode plate (2) is fixedly connected to an upper buffer layer (8), the upper buffer layer (8) is fixedly connected to an upper insulating layer (10), the upper insulating layer (10) is fixedly connected to an upper protective layer (12), and the upper protective layer (12) is provided with a quick-release assembly.

2. The flexible and bendable composite busbar device according to claim 1, characterized in that: The quick-release assembly includes two fixing plates (14), both of which are fixedly connected to the upper protective layer (12). An outer cover (19) is fixedly connected to the surface of the upper protective layer (12). Control rods (15) are slidably connected inside the two fixing plates (14). A locking block (17) is fixedly connected to the adjacent side of the two control rods (15). A fixing block (13) is provided on the surface of the two locking blocks (17). A heat sink (18) is fixedly connected to the surface of the fixing block (13).

3. The flexible and bendable composite busbar device according to claim 1, characterized in that: The positive electrode plate (1) is made of aluminum alloy, and the negative electrode plate (2) is made of aluminum alloy.

4. The flexible and bendable composite busbar device according to claim 1, characterized in that: The first middle insulating layer (3) is made of ethylene propylene rubber, the second middle insulating layer (4) is made of ethylene propylene rubber, the upper insulating layer (10) is made of ethylene propylene rubber, and the lower insulating layer (9) is made of ethylene propylene rubber.

5. The flexible and bendable composite busbar device according to claim 1, characterized in that: The first middle buffer layer (5) is made of silicone, the second middle buffer layer (6) is made of silicone, the upper buffer layer (8) is made of silicone, and the lower buffer layer (7) is made of silicone.

6. The flexible and bendable composite busbar device according to claim 1, characterized in that: The upper protective layer (12) is an epoxy powder coating, and the lower protective layer (11) is an epoxy powder coating.

7. The flexible and bendable composite busbar device according to claim 2, characterized in that: The outer cover (19) is slidably connected to the fixing block (13), and the outer cover (19) is slidably connected to the control rod (15).

8. A flexible and bendable composite busbar device according to claim 2, characterized in that: Two springs (16) are fixedly connected to opposite sides of the two blocks (17), and both springs (16) are fixedly connected to the two fixing plates (14).

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