Lightweight circulating carrier for carrier-free integrated busbar

Abstract

The utility model discloses a lightweight circulation carrier for a carrier-free integrated busbar, which comprises a cover plate, the shape of the cover plate is matched with that of an integrated busbar conducting bar, the cover plate is provided with a plurality of convex structures, the cover plate is provided with a plurality of hollow holes penetrating through the cover plate and the convex structures, and the hollow holes are communicated with the convex structures. The cover plate is embedded with the conducting bar through a convex structure to realize auxiliary positioning, and meanwhile, the stress of the busbar is buffered in the process through the design of a flange and a fillet, so that rigid damage is avoided; the collection line avoiding groove provides a three-dimensional wiring space for the cable and reduces the bending fracture risk, the cover plate forms a physical protection barrier through an integrated covering structure, welding slag splashing is blocked in the welding link, a busbar sensitive area is protected, a protruding structure and hollow holes are designed according to the busbar, the overall deformation resistance is enhanced, and the collection line avoiding groove serves as a complete covering type carrier. The lightweight design is adaptive to high-frequency circulation, the structural integrity is maintained in long-term repeated use, and the dual goals of process protection and equipment durability are synchronously achieved.

Description

Technical Field

[0001] This utility model belongs to the field of battery production equipment technology, specifically relating to a lightweight circulating carrier for carrierless integrated busbars. Background Technology

[0002] In the field of integrated busbar manufacturing, the positioning accuracy and lightweight design of tooling directly affect the processing quality and assembly efficiency of the busbars. Currently, mainstream tooling commonly uses metal frame structures or injection-molded brackets. While these structures improve positioning accuracy, the multiple layers of mechanical components result in excessive overall weight, failing to meet the lightweight requirements of carrier-free busbars. A more significant contradiction lies in the industry-standard injection-molded bracket solution's heavy weight and lack of space for data acquisition lines. This leads to frequent cable damage accidents in automated production lines, and the rigid edges are prone to scratching the surface of the busbars.

[0003] A search revealed a Chinese patent document that discloses a copper plate snap-fit ​​connection structure for an integrated busbar of a new energy battery pack [Application No.: 202420617613.9, Publication No.: CN222191074U]. The document describes a busbar frame with at least two wire harness routing grooves, and several copper plates arranged side-by-side on the sides of these grooves. While this patent solves the internal connection problem of the busbar, it does not consider issues such as lightweighting and accurate positioning required for circulation. Utility Model Content

[0004] In view of the problems existing in the prior art, the purpose of this utility model is to provide a lightweight circulating carrier for carrierless integrated busbars.

[0005] A lightweight circulating carrier for carrierless integrated busbars is characterized by comprising: a cover plate, the shape of which matches the conductive bar of the integrated busbar, the cover plate having a plurality of convex structures, and the cover plate having a plurality of perforated holes penetrating the cover plate and the convex structures.

[0006] Preferably, the convex structure is arranged according to the conductive busbar of the integrated busbar.

[0007] Through the above technical solution, the convex structure on the cover plate is designed with the arrangement of the conductive bars in the integrated busbar in mind, ensuring that each convex structure can spatially correspond to the corresponding conductive bar during actual installation. This structural design not only improves the fit between the cover plate and the conductive bar but also provides excellent guidance and auxiliary positioning during assembly. When installing the cover plate onto the integrated busbar, operators can utilize the precise alignment of the convex structure with the conductive bar to quickly identify the installation direction and position, effectively avoiding problems such as incorrect or off-center installation, and improving installation efficiency and accuracy.

[0008] Preferably, the positions of the perforated holes are arranged according to the conductive bars of the integrated busbar.

[0009] Through the above technical solution, the position of the perforated holes can precisely correspond to the distribution of the conductive bars on the integrated busbar, ensuring that the conductive bars are not obstructed or interfered with by the structure when passing through the cover plate, thereby guaranteeing the smoothness of the electrical connection and the convenience of the installation process. This hole arrangement method is customized based on a thorough analysis of the integrated busbar structure, which can maximize the fit to the actual arrangement of conductive components and avoid problems such as assembly difficulties, additional processing, or uneven stress on components caused by unreasonable hole positions.

[0010] Preferably, the edge of the hollow hole is provided with a collection line avoidance groove.

[0011] By using the above technical solution, a data acquisition line avoidance groove is set at the edge of the perforated hole, which provides a dedicated lead-out channel for the data acquisition lines on the integrated busbar, preventing the data acquisition lines from being squeezed, bent, or damaged when passing through the cover plate. This structural design fully considers the layout requirements of the data acquisition lines and is especially suitable for application scenarios where flexible lines such as temperature acquisition lines and voltage sampling lines are laid on the conductive busbar, which can effectively improve the rationality and safety of cable wiring.

[0012] Preferably, an L-shaped support is provided on one side of the lower surface of the cover plate, and a long strip support is provided on the other side of the lower surface.

[0013] Through the above technical solution, the L-shaped support and the long strip support set under the cover plate together constitute a structurally stable support system. While achieving an effective connection between the cover plate and the integrated busbar, it also improves the overall mechanical performance and installation stability. Among them, the L-shaped support, through the combination of its vertical and horizontal parts, can not only form a stable contact with the busbar or mounting surface, but also facilitates functions such as snapping, limiting, or lateral locking, providing good structural guidance and installation assistance. The long strip support provides a larger area of ​​support, which helps to distribute the load of the cover plate in the vertical direction and prevent warping, deformation, or loosening caused by local stress concentration. It is especially suitable for cover plates with long dimensions or thin walls, improving the overall flatness while also enhancing its vibration resistance and long-term structural reliability.

[0014] Preferably, the lower surface of the cover plate is provided with a flange surrounding the perforated hole, the inner wall contour of which matches the shape of the perforated hole.

[0015] By employing the aforementioned technical solution, a flange structure with a shape perfectly matching the perforated hole is set around it, effectively enhancing the structural integrity and functional versatility of the hole. This flange forms a recessed or surrounding structural boundary in space, providing circumferential support for the conductive busbar or connecting components passing through the hole when the component is perforated, thereby preventing wobbling or displacement and improving installation accuracy.

[0016] Preferably, the surface edge of the flange that contacts the integrated busbar has rounded corners.

[0017] The above technical solution employs a rounded corner design at the flange edge, effectively reducing potential mechanical damage or insulation wear to the integrated busbar body, data acquisition lines, or other electronic components caused by sharp edges. During the operation of the cyclic carrier, due to vibration, thermal expansion, or structural fretting, if the contact edge is sharp, it can easily cause scratches, cuts, or indentations to the busbar or cable over long-term contact, thus creating potential electrical safety hazards.

[0018] Compared with the prior art, the present invention has the following advantages:

[0019] 1. This utility model's cover plate achieves auxiliary positioning through a convex structure that fits into the conductive busbar. Simultaneously, the rounded corner design of the flange buffers the force on the busbar during processing, preventing rigid damage. The acquisition line avoidance groove provides three-dimensional routing space for the cable, reducing the risk of bending and breakage. All these structures work together to form a three-dimensional constraint system, which not only enhances the stability of the main positioning system but also prevents process damage, significantly improving production safety.

[0020] 2. The cover plate of this utility model forms a physical protective barrier with an integrated covering structure, which blocks welding slag splash during the welding process and protects the sensitive area of ​​the busbar. The raised structure and hollow holes designed according to the busbar enhance the overall resistance to deformation. As a complete covering carrier, its lightweight design is suitable for high-frequency circulation and maintains structural integrity during long-term repeated use, thus achieving the dual goals of process protection and equipment durability. Attached Figure Description

[0021] Figure 1 This is a three-dimensional schematic diagram of the present invention;

[0022] Figure 2 This is a partially enlarged schematic diagram of point A of this utility model;

[0023] Figure 3 This is a side view of the present invention.

[0024] In the figure: 101, long strip cover plate; 102, convex structure; 103, hollow hole; 104, acquisition line avoidance groove; 105, flange; 201, L-shaped support; 202, long strip support. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Please see Figures 1 to 3 This utility model provides a technical solution:

[0027] A lightweight circulating carrier for carrierless integrated busbars is characterized by comprising: a cover plate 101, the shape of which matches the conductive bar of the integrated busbar, the cover plate 101 having a plurality of convex structures 102, and the cover plate 101 having a plurality of hollow holes 103 penetrating the cover plate 101 and the convex structures 102.

[0028] In the process of installing the integrated busbar into the battery, the cover plate 101, through its convex structure 102 and the matching relationship with the conductive busbar, achieves precise positioning of the integrated busbar, ensuring the stability of the installation position and the efficiency of the assembly process. Simultaneously, in the process of welding the integrated busbar to the battery, the cover plate 101 acts as a protective cover, effectively preventing weld slag splashes and dust particles from intruding during welding, ensuring the cleanliness and safety of the battery and its connecting components, and improving welding quality and subsequent reliability.

[0029] Specifically, the convex structures 102 are arranged according to the conductive bars of the integrated busbar. The convex structures 102 on the cover plate 101 are designed with the arrangement of the conductive bars in the integrated busbar in mind, ensuring that each convex structure 102 can spatially correspond to its corresponding conductive bar during actual installation. This structural design not only improves the fit between the cover plate 101 and the conductive bars but also provides excellent guidance and auxiliary positioning during assembly. When installing the cover plate 101 onto the integrated busbar, operators can utilize the precise alignment of the convex structures 102 with the conductive bars to quickly identify the installation direction and position, effectively avoiding misinstallation or offset installation, and improving installation efficiency and accuracy.

[0030] Furthermore, the convex structure 102, while assisting in positioning, also serves as a physical limiter, helping to maintain the stability of the cover plate 101 on the busbar during the cyclic operation or transportation of the vehicle. This reduces the risk of displacement due to vibration, impact, and other factors, further improving the overall structural reliability and service life of the system. It is particularly suitable for electrical system scenarios with compact structures, dense wiring, or high installation accuracy requirements, and has broad application value.

[0031] Specifically, the positions of the perforated holes 103 are arranged according to the conductive bars of the integrated busbar. The positions of the perforated holes 103 precisely correspond to the distribution of the conductive bars on the integrated busbar, ensuring that the conductive bars are not obstructed or interfered with by the structure when passing through the cover plate 101, thereby guaranteeing the smoothness of the electrical connection and the convenience of the installation process. This hole arrangement method is a customized design based on a thorough analysis of the integrated busbar structure, which can maximize the fit to the actual arrangement of conductive components and avoid problems such as assembly difficulties, additional processing, or uneven stress on components caused by unreasonable through hole positions.

[0032] Meanwhile, this targeted perforation structure facilitates electrical connections, sampling line routing, thermal management, and subsequent testing. In practical applications, the accurately positioned perforated holes 103 not only improve the fit between the cover plate 101 and the busbar but also enhance the overall performance of the system in terms of electrical insulation, heat dissipation and ventilation, and wiring management. It is particularly suitable for integrated electrical systems with high requirements for space utilization, electrical performance, and assembly efficiency, offering significant advantages in engineering applications.

[0033] Specifically, a data acquisition line avoidance groove 104 is provided on the edge of the perforated hole 103. This groove provides a dedicated exit channel for the data acquisition lines on the integrated busbar, preventing them from being squeezed, bent, or damaged when passing through the cover plate 101. This structural design fully considers the layout requirements of the data acquisition lines and is particularly suitable for applications where flexible lines such as temperature acquisition lines and voltage sampling lines are laid on the busbar, effectively improving the rationality and safety of cable routing.

[0034] Furthermore, the clearance groove 104 prevents the acquisition cable from directly contacting the edge of the cover plate 101, thereby reducing the risk of insulation wear caused by friction or vibration during long-term operation and improving the electrical safety and long-term operational reliability of the system. This detailed design also facilitates the visual management of wiring, making it more intuitive and convenient for maintenance personnel to inspect or replace the acquisition cable later, further enhancing the maintainability and ergonomics of the entire system.

[0035] In summary, the acquisition line avoidance groove 104 not only optimizes the structural function, but also reflects a deep consideration of the safety and reliability of system wiring, making it suitable for high-density, modular integrated busbar systems.

[0036] Specifically, an L-shaped support 201 is provided on one side of the lower surface of the cover plate 101, and a long strip support 202 is provided on the other side of the lower surface. The L-shaped support 201 and the long strip support 202 together constitute a structurally stable support system, which effectively connects the cover plate 101 to the integrated busbar while improving the overall mechanical performance and installation stability. The L-shaped support 201, through the combination of its vertical and horizontal parts, not only forms a stable contact with the busbar or mounting surface, but also facilitates functions such as snapping, limiting, or lateral locking, providing excellent structural guidance and installation assistance. The long strip support 202 provides a larger area of ​​support, helping to distribute the load on the cover plate 101 in the vertical direction and preventing warping, deformation, or loosening caused by localized stress concentration. It is particularly suitable for long or thin-walled cover plates 101, improving overall flatness while enhancing its vibration resistance and long-term structural reliability.

[0037] This combined support structure also effectively improves the ease of operation during installation. The L-shaped support 201 plays a role in initial positioning and limiting guidance, while the long strip support 202 provides stable support during the final placement process, forming an efficient and coordinated installation mechanism. It is suitable for circulating system equipment with high requirements for component installation accuracy and structural reliability.

[0038] Specifically, the lower surface of the cover plate 101 is provided with a flange 105 surrounding the perforated hole 103. The inner wall contour of the flange 105 matches the shape of the perforated hole 103. The flange 105 structure, perfectly matching the shape of the perforated hole 103, effectively enhances the structural integrity and functional versatility of the hole. The flange 105 forms a recessed or surrounding structural boundary in space, providing surrounding support for the conductive busbar or connecting parts passing through the hole when components are perforated, thus preventing wobbling or displacement and improving installation accuracy. Furthermore, this design enhances the rigidity of the hole, preventing structural weakness or deformation of the cover plate 101 due to localized openings. It exhibits superior stability and service life, especially in complex working environments such as high-frequency vibration and thermal expansion and contraction. The flange 105 can also serve as a pre-installation area for seals, insulating sleeves, or flexible clips, providing reserved space and installation guidance for subsequent assembly, further enhancing the synergistic assembly and modularity between components.

[0039] Meanwhile, since the inner wall contour of the flange 105 maintains the same shape as the hollow hole 103, it facilitates high consistency in forming during automated processing and precision manufacturing, reducing production errors and improving product consistency and yield. This structure is particularly suitable for cyclic vehicle scenarios with high requirements for through-hole accuracy, electrical isolation, and structural strength, providing a structural foundation for subsequent functional expansion.

[0040] Specifically, the surface edge of the flange 105 that contacts the integrated busbar is rounded. This rounded edge design effectively reduces the mechanical damage or insulation wear that sharp edges may cause to the integrated busbar body, data acquisition lines, or other electronic components. During the operation of the cyclic carrier, vibration, thermal expansion, or structural micro-movements can easily cause scratches, cuts, or indentations to the busbar or cables over long-term contact if the contact edge is sharp, thus creating potential electrical safety hazards. The rounded edge structure achieves a more uniform stress distribution. Even with slight relative displacement during installation or operation, no stress concentration points will form, significantly improving the fatigue resistance and durability of the structure. Furthermore, the rounded edge also has good guiding characteristics, facilitating sliding alignment during installation. This allows the busbar, data acquisition lines, or related components to smoothly pass through or mate with the holes, reducing assembly resistance and improving assembly efficiency and consistency.

[0041] From a manufacturing perspective, rounded corner design helps improve the feasibility and lifespan of mold processing, and reduces the risk of sharp edges forming defects such as burrs and cracks in the mold. Overall, this rounded corner structure not only optimizes the mechanical compatibility of the product, but also has significant advantages in safety, electrical reliability, and manufacturing process, making it a preferred design solution for high-reliability vehicle systems.

[0042] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0043] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0044] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A lightweight circulating carrier for carrierless integrated busbars, characterized in that, include: Cover plate (101), the shape of the cover plate (101) matches the integrated busbar conductive busbar, the cover plate (101) is provided with a number of convex structures (102), and the cover plate (101) is provided with a number of hollow holes (103) penetrating the cover plate (101) and the convex structures (102).

2. The cyclic vehicle according to claim 1, characterized in that: The convex structure (102) is arranged according to the conductive busbar of the integrated busbar.

3. The cyclic vehicle according to claim 1, characterized in that: The location of the hollow holes (103) is arranged according to the conductive busbars of the integrated busbar.

4. The cyclic vehicle according to claim 1, characterized in that: The edge of the hollow hole (103) is provided with a collection line avoidance groove (104).

5. The cyclic vehicle according to claim 1, characterized in that: The cover plate (101) has an L-shaped support (201) on one side of its lower surface and a long strip support (202) on the other side of its lower surface.

6. The cyclic vehicle according to claim 1, characterized in that, The lower surface of the cover plate (101) is provided with a flange (105) surrounding the hollow hole (103), the inner wall contour of which matches the shape of the hollow hole (103).

7. The cyclic vehicle according to claim 6, characterized in that, The flange (105) has a rounded edge on the surface that contacts the integrated busbar.

Images