Integrally-formed energy storage connector for connecting soft copper bar

Abstract

The utility model discloses an integrally-formed energy storage connector connected with a soft copper bar, and relates to the technical field of energy storage connectors, the integrally-formed energy storage connector comprises the soft copper bar, the soft copper bar is divided into an exposed area and welding areas, the welding areas are located at the two ends of the exposed area, the exposed area is bent upwards to form an arc shape, through holes are formed in the welding areas, and the through holes are communicated with the exposed area. A through hole is formed in the welding area, a torsion spring sleeve is arranged in the through hole, the exposed area is sleeved with a double-layer adhesive heat shrink tube, an installation shell is installed on the welding area, and a circulation channel used for being matched with the torsion spring sleeve and the soft copper bar is formed in the installation shell. The soft copper bar and the mounting shell are integrally and stably connected, so that the electrical performance is improved, the assembly process is simplified, and the reliability and adaptability of the product are enhanced.

Description

Technical Field

[0001] This application relates to the field of energy storage connector technology, and in particular to an integrated flexible copper busbar energy storage connector. Background Technology

[0002] The rapid development of energy storage technology has driven profound changes in the energy sector, demonstrating enormous potential in areas such as automated power management, efficient utilization of new energy sources, and improved grid stability. Particularly in applications on the user and power supply sides, energy storage technology not only promotes the efficient allocation of power resources but also significantly improves the economic and environmental benefits of energy use. With the continuous upgrading and optimization of energy storage systems, connectors, as key components, are becoming increasingly important in ensuring the reliability of power transmission and the overall performance of the system.

[0003] Currently, in order to achieve stable connections between different electrical devices, traditional crimping processes are commonly used to fix cables and terminals. This mainly involves mechanically pressing metal terminals and wires together, supplemented by insulation measures to ensure safe operation. In addition, methods such as soldering are also widely used. Although these methods can meet basic requirements to a certain extent, they generally suffer from high operational complexity and high cost.

[0004] However, repeated processing in the traditional way can easily lead to poor contact or increased resistance, which in turn affects the normal operation of the entire circuit system. Therefore, there is an urgent need for a solution that can effectively simplify the assembly process while ensuring good electrical connection quality. Utility Model Content

[0005] To improve upon the problems of complex operation and poor contact or increased resistance caused by traditional cable and terminal connection methods, this application provides an integrated flexible copper busbar energy storage connector.

[0006] The integrated molded flexible copper busbar energy storage connector provided in this application adopts the following technical solution:

[0007] An integrated flexible copper busbar energy storage connector includes a flexible copper busbar, which is divided into an exposed area and a soldering area. The soldering area is located at both ends of the exposed area. The exposed area is bent upward to form an arc shape. Through holes are formed in each soldering area, and torsion spring sleeves are installed in the through holes. Double-layer adhesive heat shrink tubing is fitted on the exposed area. An mounting shell is installed on the soldering area, and a flow channel for mates with the torsion spring sleeves and the flexible copper busbar is formed in the mounting shell.

[0008] By adopting the above technical solution, the exposed area of ​​the soft copper busbar is bent upward to form an arc shape, which can achieve the shortest distance connection between non-coaxial PACK packages, thereby effectively reducing energy loss during power transmission. Through holes are opened in the welding area and torsion spring sleeves are installed. Simultaneously, flow channels are opened in the mounting housing to ensure a stable assembly of the soft copper busbar with other connector components, reducing the instability and high resistance problems caused by traditional crimping processes and improving the stability of power transmission. Double-layer adhesive heat shrink tubing covers the exposed area, further improving the product's safety performance while meeting IP67 waterproof and insulation requirements.

[0009] Optionally, the soft copper busbar is formed by stacking 0.1mm T2 copper sheets.

[0010] By adopting the above technical solution, the soft copper busbar is formed by stacking multiple layers of 0.1mm T2 copper sheets, which improves the overall conductivity and mechanical strength of the soft copper busbar, while reducing the risk of breakage due to insufficient single-layer thickness. This allows the connector to have higher reliability while ensuring excellent conductivity, making it suitable for energy storage connection needs under various complex working conditions.

[0011] Optionally, the flow channel includes a transverse channel for limiting the welding area and a vertical channel for limiting the torsion spring sleeve.

[0012] By adopting the above technical solution, the horizontal channel limits the installation of both ends of the soft copper busbar, and the vertical channel limits the installation of the torsion spring sleeve, thereby improving the overall stability and firmness of the installation.

[0013] Optionally, the upper surface of the mounting shell is provided with grooves arranged in a linear array, and the side of the mounting shell is provided with trapezoidal recesses.

[0014] By adopting the above technical solution, the linearly arranged grooves increase the friction on the surface of the mounting shell, making it easier for operators to grip and fix the connector, thus improving assembly efficiency; the trapezoidal recesses on the side of the mounting shell reduce the overall weight while ensuring structural strength, improving material utilization, and reserving space for future expansion of functions or cooperation with other components.

[0015] Optionally, the mounting housing is provided with threaded grooves that mate with other functional accessories.

[0016] By adopting the above technical solutions, the connector can be securely connected with other functional components, improving the stability and reliability of the overall structure, while simplifying the assembly process and reducing installation complexity.

[0017] Optionally, each end of the double-layer adhesive thermoplastic tube is provided with a snap-fit ​​groove, and the snap-fit ​​surface of the snap-fit ​​groove fits into the end face of the mounting shell.

[0018] By adopting the above technical solution, the snap-fit ​​surface of the snap-fit ​​groove can fit tightly with the end face of the mounting shell, effectively improving the sealing and stability between the heat shrink tubing and the mounting shell, preventing external impurities or moisture from entering, further improving the overall waterproof performance and electrical insulation performance of the connector, and ensuring the safety and reliability of the electrical transmission process.

[0019] Optionally, the ratio of the coverage area of ​​the welding area to the coverage area of ​​the exposed area is 1:2~3.

[0020] By adopting the above technical solutions, the reliability of electrical connections is ensured while maximizing the effective conductive area of ​​the exposed region, further reducing resistance and improving the stability of electrical transmission.

[0021] Optionally, the soft copper busbar is made of nylon with glass fiber, and the double-layer adhesive heat shrink tubing is made of polyolefin.

[0022] By adopting the above technical solutions, the nylon plus glass fiber connector has higher mechanical strength and temperature resistance, and can remain stable in complex operating environments; the double-layer adhesive heat shrink tubing is made of polyolefin, which ensures good insulation and waterproof performance, further improving the safety and reliability of the product.

[0023] In summary, this application includes at least one of the following beneficial technical effects:

[0024] 1. By bending the exposed area of ​​the soft copper busbar upwards in an arc, the shortest distance connection between non-same-layer PACKs is achieved, reducing energy loss during power transmission and improving transmission efficiency;

[0025] 2. The welding areas at both ends of the soft copper busbar and the torsion spring sleeve are matched, which reduces the cable and terminal crimping process and avoids the problem of excessive resistance caused by unstable crimping, thereby improving the stability of electrical transmission;

[0026] 3. Double-layer adhesive heat shrink tubing covers the exposed area of ​​the soft copper busbar and is integrally injection molded, which enhances the connector's waterproof and insulation performance, making it better suited for different working environments;

[0027] 4. The flow channels on the mounting housing ensure a secure assembly of the soft copper busbar with other connector components, reducing instability and high resistance issues caused by traditional crimping processes and improving electrical transmission stability. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the overall structure shown in this application.

[0030] Figure 2 This application presents an exploded view of the overall structure.

[0031] Figure 3 This is a cross-sectional view showing the overall structure of this application.

[0032] Figure 4 This application demonstrates Figure 3 A partial sectional view.

[0033] Reference numerals: 1. Soft copper busbar; 11. Exposed area; 12. Welding area; 2. Perforation; 3. Torsion spring sleeve; 4. Double-layer adhesive heat shrink tubing; 5. Mounting shell; 6. Flow channel; 61. Horizontal channel; 62. Vertical channel; 7. Groove; 8. Threaded groove; 9. Recess. Detailed Implementation

[0034] The following is in conjunction with the appendix Figure 1 -Appendix Figure 4 This application will be described in further detail.

[0035] This application discloses an integrated energy storage connector with a flexible copper busbar 1.

[0036] Reference Figure 1 and Figure 2 As shown, the device includes a flexible copper busbar 1, a torsion spring sleeve 3, a double-layer adhesive heat shrink tubing 4, and a mounting shell 5. The flexible copper busbar 1 has an exposed area 11 and a welded area 12. The ratio of the coverage area of ​​the welded area 12 to the coverage area of ​​the exposed area 11 is between 1:2 and 3. The coverage area of ​​the exposed area 11 can be adjusted appropriately according to actual needs to improve adaptability. The welded area 12 is located at both ends of the exposed area 11, which is the middle of the flexible copper busbar 1. The flexible copper busbar 1 and the torsion spring sleeve 3 cooperate to form a stable mechanical connection structure. The double-layer adhesive heat shrink tubing 4 wraps the exposed area 11 of the flexible copper busbar 1 to provide insulation protection. The mounting shell 5 is set on the welded area 12 to fix and support it, achieving efficient and stable electrical transmission.

[0037] For details, see Figure 2 As shown, the flexible copper busbar 1 is made of multiple pieces of T2 copper, each with a thickness of approximately 0.1 mm. These pieces are stacked to form a conductive component with a certain degree of flexibility. The flexible copper busbar 1 is bent upwards into an arc shape in the middle, and welding areas 12 are provided at both ends. A torsion spring sleeve 3 is inserted through the through hole 2 to achieve positioning and fixation. The flexible copper busbar 1 is made of nylon with glass fiber reinforcement, which allows the connector to be used in high and low temperature environments and meet functional requirements.

[0038] See Figure 2 As shown, the double-layer adhesive heat shrink tubing 4 is made of polyolefin material, which can effectively cover the exposed part of the soft copper busbar 1, forming a high-strength waterproof insulation layer. The heat shrink tubing has locking grooves at both ends, with a stepped cross-section, allowing for a better and more perfect fit with the end face of the mounting shell 5. This improves the sealing and stability between the double-layer adhesive heat shrink tubing 4 and the mounting shell 5, preventing external impurities or moisture from intruding, further enhancing the overall waterproof and electrical insulation performance of the connector, and ensuring safe and reliable electrical transmission.

[0039] See Figure 1 As shown, the top of the mounting housing 5 has regularly arranged small grooves 7, and the sides have trapezoidal recesses 9. The linearly arranged grooves 7 increase the friction on the surface of the mounting housing 5, making it easier for operators to grip and fix the connector, thus improving assembly efficiency. The trapezoidal recesses 9 on the sides of the mounting housing 5 reduce the overall weight while ensuring structural strength, improving material utilization, and reserving space for future functional expansion or integration with other components. In addition, the bottom of the mounting housing 5 has a threaded groove 8, which can be used to connect with other functional accessories, such as sensor probes, so that the connector and other functional accessories are securely connected, improving the stability and robustness of the overall structure. The threaded assembly simplifies the assembly process and reduces the complexity of installation. The groove 7 can be designed with adjustable depth and spacing parameters to make the overall structure more compact and reasonable. The recess 9 can be designed with optimized geometry based on actual stress conditions, enhancing the grip and improving aesthetics.

[0040] See Figure 3 and Figure 4 As shown, the mounting housing 5 has a flow channel 6 for cooperating with the torsion spring sleeve 3 and the soft copper busbar 1. The flow channel 6 is further divided into a transverse channel 61 for limiting the welding area 12 and a vertical channel 62 for limiting the torsion spring sleeve 3. The transverse channel 61 and the vertical channel 62 are interconnected and vertically distributed. The accessories are limited and fastened by the transverse channel 61 and the vertical channel 62 respectively, which improves the stability and reliability of the installation.

[0041] The implementation principle of the integrated energy storage connector with a flexible copper busbar 1 in this application embodiment is as follows: the exposed area 11 of the flexible copper busbar 1 is bent upward in an arc to achieve the shortest distance connection between non-column PACKs, reducing power transmission loss. After the two ends of the molding and sealing parts are welded, the female end torsion spring sleeve 3 is pressed in. The flexible copper busbar 1 and the torsion spring sleeve 3 are placed in the mold and integrally injection molded. After injection molding, double-layer adhesive heat shrink tubing 4 is put on to cover the exposed area 11 of the flexible copper busbar 1. After heat shrinking in a tunnel oven, the exposed area 11 meets the IP67 waterproof and insulation performance, and the mounting shell 5 is provided with a flow channel 6 to ensure the stable assembly of the two ends of the flexible copper busbar 1 and other components of the connector, reduce the instability and high resistance problems caused by the crimping process, and improve the stability of power transmission.

[0042] Unless otherwise defined, the technical or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," "third," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The terms "a" or "an," and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising," "including," and similar terms mean that the elements or objects preceding "comprising" encompass the elements or objects listed following "comprising" or "including," and their equivalents, but do not exclude other elements or objects. "Above," "below," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0043] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A one-piece molded energy storage connector with a flexible copper busbar, characterized in that: The system includes a soft copper busbar (1), which is divided into an exposed area (11) and a welding area (12). The welding area (12) is located at both ends of the exposed area (11). The exposed area (11) is bent upward to form an arc shape. The welding area (12) is provided with perforations (2). A torsion spring sleeve (3) is provided in the perforations (2). The exposed area (11) is fitted with a double-layer adhesive heat shrink tubing (4). An installation shell (5) is installed on the welding area (12). A flow channel (6) is provided in the installation shell (5) for cooperating with the torsion spring sleeve (3) and the soft copper busbar (1).

2. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The soft copper busbar (1) is formed by stacking 0.1mm T2 copper sheets.

3. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The flow channel (6) includes a transverse channel (61) for limiting the welding area (12) and a vertical channel (62) for limiting the torsion spring sleeve (3).

4. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The mounting shell (5) has grooves (7) arranged in a linear array on its upper surface, and trapezoidal recesses (9) are formed on the side of the mounting shell (5).

5. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The mounting housing (5) has threaded grooves (8) that cooperate with other functional accessories.

6. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The ends of the double-layer adhesive thermoplastic tubes are all formed with snap-fit ​​grooves, and the snap-fit ​​surfaces of the snap-fit ​​grooves are in contact with the end faces of the mounting shell (5).

7. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The ratio of the coverage area of ​​the welding area (12) to the coverage area of ​​the exposed area (11) is 1:2~3.

8. The integrated flexible copper busbar energy storage connector according to claim 1, characterized in that: The soft copper busbar (1) is made of nylon with glass fiber, and the double-layer adhesive heat shrink tubing (4) is made of polyolefin.

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