Conductive connection structure of busbar
By combining multiple layers of soft conductive strips and rigid conductors, the problems of busbar loosening and high cost are solved, thereby improving reliability and safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- TOYOTA JIDOSHA KK
- Filing Date
- 2025-05-21
- Publication Date
- 2026-05-19
AI Technical Summary
The gaps between the layers of soft copper busbars in the busbar are compressed under the pre-tightening force, which leads to loosening, poor conductive contact, increased production costs and safety hazards.
The busbar uses a multi-layer soft conductive strip stack, combined with rigid conductors and fasteners for interference fit, avoiding loosening caused by deformation, and achieving conductive connection through direct contact, eliminating the need for diffusion soldering and nickel strip addition.
It improves the reliability and safety of conductive connections, reduces production costs, avoids the risks of poor contact and overheating, and increases the yield rate.
Smart Images
Figure CN224264387U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of bus technology, and in particular to a conductive connection structure for a bus. Background Technology
[0002] After the busbar ends are hardened by diffusion soldering, they are bolted to the conductive components. However, microscopically, it's impossible to completely eliminate gaps between the layers of soft copper busbars after diffusion soldering. These gaps can be compressed (creep) under long-term preload, leading to a decrease in preload and loosening at the connection between the busbar and the conductive components. This results in poor conductive contact, making the connection prone to overheating or arcing, and potentially causing battery fires and other safety accidents. Furthermore, current technology requires diffusion soldering multiple soft copper busbars to form a single unit, but diffusion soldering is costly and difficult to control in terms of quality. To ensure conductivity, nickel sheets are also added to the contact surfaces, further increasing production costs. Utility Model Content
[0003] In view of this, the present invention provides a conductive connection structure for a busbar to solve the technical problems of poor conductive contact and high production cost.
[0004] To achieve the above objectives, this utility model provides a conductive connection structure for a bus, comprising:
[0005] A busbar composed of multiple layers of soft conductive strips stacked together, wherein the ends of the busbar have openings;
[0006] A rigid conductor having an inner hole is interference-fitted into the opening;
[0007] Rigid conductive components;
[0008] Fasteners;
[0009] The fastener passes sequentially through the inner hole of the conductor, the inner hole of the conductive component, and the fixing member to achieve a conductive connection between the busbar and the conductive component; wherein, the supporting surface of the fastener is in direct contact with one end face of the conductor, and the other end face of the conductor is in direct contact with the plane of the conductive component.
[0010] Optionally, the fastener includes a support portion and a connecting portion perpendicularly connected to the support portion, wherein the support surface of the support portion is in direct contact with one end face of the conductor, and the connecting portion passes sequentially through the conductor, the inner hole of the conductive component, and the fixing member.
[0011] Optionally, the contact surface between the conductor and the busbar is not exposed in the support portion.
[0012] Optionally, the contact area between the other end face of the conductor and the conductive component is greater than or equal to the main cross-sectional area of the busbar.
[0013] Optionally, the contact area between the outer surface of the conductor and the inner surface of the opening of the busbar is greater than or equal to the cross-sectional area of the main body of the busbar.
[0014] Optionally, the height of the conductor is greater than or equal to the thickness of the busbar.
[0015] Optionally, the conductor is cylindrical, and the fastener is a female thread.
[0016] Optionally, the conductive connection structure is used for conductive connection between the vehicle power battery and the inverter and / or electrical components.
[0017] Optionally, the conductor is made of copper.
[0018] Optionally, the fastener is a bolt.
[0019] This utility model embodiment can avoid the risk of loosening at the connection between the busbar and the conductive component due to the decrease in preload caused by busbar deformation, thereby improving the reliability and safety of the conductive connection; moreover, it does not require diffusion welding of the busbar to harden the charged layer combination, nor does it require adding nickel sheets to the contact surface to reduce contact resistance, which helps to ensure yield and reduce production costs.
[0020] The further effects of the aforementioned unconventional alternative methods will be explained below in conjunction with specific implementation methods. Attached Figure Description
[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0022] Figure 1 This is a schematic diagram of the conductive connection structure of a bus according to an embodiment of the present invention;
[0023] Figure 2 This is a top view of the conductive connection structure of a bus according to an embodiment of the present invention;
[0024] Figure 3 This is a dimensional schematic diagram of the conductive connection structure of the busbar according to an embodiment of the present utility model.
[0025] The attached figures are labeled as follows:
[0026] 1-Bus;
[0027] 2-Conductor;
[0028] 3-Conductive components;
[0029] 4-Factors;
[0030] 5-Fasteners;
[0031] 51-Support section;
[0032] 52-Connecting part. Detailed Implementation
[0033] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention 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 invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.
[0034] 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", "axial", "circumferential", "radial", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element 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.
[0035] 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 indicated technical features. 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.
[0036] This utility model embodiment provides a conductive connection structure for a busbar, such as... Figure 1As shown, the conductive connection structure of the bus includes a bus 1 composed of multiple layers of soft conductive strips stacked together, a rigid conductor 2, a rigid conductive component 3, a fixing member 4, and a fastener 5. The bus 1 has an opening at one end, and the conductor 2 has an inner hole and is interference-fitted into the opening. The fastener 5 passes sequentially through the inner hole of the conductor 2, the conductive component 3, and the fixing member 4 to achieve a conductive connection between the bus 1 and the conductive component 3. The supporting surface of the fastener 5 is in direct contact with one end face of the conductor 2, and the other end face of the conductor 2 is in direct contact with the plane of the conductive component 3. Therefore, the bus 1 is conductively connected to the conductor 2, and the conductor 2 is conductively connected to the conductive component 3. The end of the fastener 5 away from the conductor 2 is fixedly connected to the fixing member 4, such that the supporting surface of the fastener 5 is in direct contact with one end face of the conductor 2, while the other end face of the conductor 2 is in direct contact with the plane of the conductive component 3. Figure 1 As shown by the solid arrow in the diagram, the current in busbar 1 flows through conductor 2 and then into conductive component 3, thereby achieving a conductive connection between busbar 1 and conductive component 3.
[0037] In the axial force path of the conductive connection structure, since a rigid conductor is used instead of a flexible busbar, and the conductor bears the axial force, the risk of loosening at the connection between the busbar and the conductive component due to a decrease in preload caused by busbar deformation can be avoided, thereby improving the reliability and safety of the conductive connection. Furthermore, this embodiment uses a rigid conductor directly press-fitted onto the busbar, eliminating the need for diffusion soldering to harden the charged layer assembly and the need to add nickel sheets to the contact surface to reduce contact resistance. This not only ensures high yield but also reduces production costs.
[0038] It should be noted that in the embodiments of this utility model, hard and soft are relative terms. The hardness of conductor 2 is greater than that of busbar 1, and the hardness of conductive component 3 is also greater than that of busbar 1.
[0039] The opening at the end of bus 1 can be of any shape, such as triangular, circular, elliptical, rectangular, square, or irregular, and this embodiment of the present invention does not impose any limitation on this. Accordingly, the shape of conductor 2 is adapted to the opening at the end of bus 1 so that conductor 2 is interference-fitted into the opening.
[0040] The end of the fastener 5 can pass through from one side of the fixing member 4 to the other side, or it can only pass through from one side of the fixing member 4 without passing through from the other side (i.e., stay inside the fixing member 4). The relationship between the fastener 5 and the fixing member 4 should be understood as any connection form that can achieve a fixed connection between the two and achieve the purpose of this utility model.
[0041] In some embodiments of the utility model, the opening at the end of the busbar 1 is circular. Correspondingly, the conductor 2 can be cylindrical, the fastener 4 can be threaded, and the end of the fastener 5 away from the conductor 2 has an external thread, so that the fastener 5 can be screwed together with the fastener 4, thereby making the supporting surface of the fastener 5 directly contact one end face of the conductor 2, while the other end face of the conductor 2 directly contactes the plane of the conductive component 3.
[0042] In some embodiments of this utility model, the fastener 5 includes a support portion 51 and a connecting portion 52 perpendicularly connected to the support portion 51. The support surface of the support portion 51 is in direct contact with one end face of the conductor 2. The connecting portion 52 passes through the conductor 2, the inner hole of the conductive component 3, and the fixing member 4 in sequence. It should be noted that the end of the support portion 51 away from the conductor 2 has an external thread. The fastener 5 is screwed together with the fixing member 4, so that the surface of the support portion 51 is in direct contact with one end face of the conductor 2, while the other end face of the conductor 2 is in direct contact with the plane of the conductive component 3. Optionally, the fastener 5 can be a bolt, which is firmly screwed together with the fixing member 4, thereby firmly assembling the conductor 2 in the opening of the busbar 1 and preventing loosening at the connection between the busbar 1 and the conductive component 3.
[0043] Optionally, such as Figure 1-2 As shown, the contact surface between conductor 2 and busbar 1 is not exposed on the support portion 51. That is, the orthographic projection of the contact surface between conductor 2 and busbar 1 on the support portion 51 (e.g.) Figure 2 (As shown by the dashed line in the figure) is located inside the support 51, so that the contact surface between the conductor 2 and the busbar 1 can be limited by the fastener 5, preventing the busbar 1 from falling off the conductor 2, which helps to further improve the reliability and safety of the conductive connection.
[0044] Optionally, the contact area between the other end face of conductor 2 and conductive component 3 is greater than or equal to the main cross-sectional area of busbar 1, such as... Figure 3 As shown, the contact area S1 between conductor 2 and conductive component 3 can be expressed as π / 4 (D 2 -d 2 The main cross-sectional area of bus 1 refers to the flow area of the portion of bus 1 without openings. The main cross-sectional area S2 of bus 1 can be expressed as L*H. Where D represents the outer diameter of the conductor, d represents the inner diameter of the conductor, L represents the width of the bus, and H represents the thickness of the bus. Since the current will flow through the contact surface between conductor 2 and conductive component 3 (the connected component), the contact area S1 is increased, and S1 ≥ S2, i.e., π / 4 (D*H) * S2. 2 -d 2 If the contact resistance is greater than or equal to L*H, the contact surface between conductor 2 and conductive component 3 can be reduced, thus preventing the contact surface from becoming a bottleneck that limits the current and reducing unnecessary current loss.
[0045] Optionally, the contact area between the outer surface of conductor 2 and the inner surface of the opening of busbar 1 is greater than or equal to the main cross-sectional area of busbar 1, such as... Figure 3 As shown, the contact area S3 between the outer surface of conductor 2 and the inner surface of the opening of busbar 1 can be expressed as πD*H. Since current will flow through the contact surface between conductor 2 and busbar 1, increasing this contact area and making S3≥S2, i.e., πD*H≥L*H, can be simplified to πD≥L. This reduces the contact resistance and prevents the contact surface between conductor 2 and busbar 1 from becoming a bottleneck restricting current, thereby reducing unnecessary current loss.
[0046] Optionally, the height of conductor 2 is greater than or equal to the thickness of busbar 1. Since the inner surface of the opening of busbar 1 is a flow surface, this height relationship can prevent part of the flow surface from extending beyond the upper or lower edge of conductor 2, which would lead to increased contact resistance and unnecessary current loss.
[0047] Optionally, the conductive connection structure provided in this embodiment of the present invention can be used for conductive connection between the vehicle power battery and the inverter and / or electrical components to ensure the reliability and safety of the electrical connection of these components. Optionally, the conductor 2 is made of copper, which helps to improve the conductivity of the conductor 2, thereby improving the conductivity between the busbar 1 and the conductive component 3.
[0048] The specific embodiments described above do not constitute a limitation on the scope of protection of this utility model. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can occur depending on design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.
Claims
1. A conductive connection structure for a busbar, characterized in that, include: A busbar composed of multiple layers of soft conductive strips stacked together, wherein the ends of the busbar have openings; A rigid conductor having an inner hole is interference-fitted into the opening; Rigid conductive components; Fasteners; A fastener passes sequentially through the inner hole of the conductor, the conductive component, and the fixing member to achieve a conductive connection between the busbar and the conductive component; wherein, the supporting surface of the fastener is in direct contact with one end face of the conductor, and the other end face of the conductor is in direct contact with the plane of the conductive component.
2. The conductive connection structure of the busbar according to claim 1, characterized in that, The fastener includes a support portion and a connecting portion perpendicularly connected to the support portion. The support surface of the support portion is in direct contact with one end face of the conductor. The connecting portion passes through the conductor, the inner hole of the conductive component, and the fixing member in sequence.
3. The conductive connection structure of the busbar according to claim 2, characterized in that, The contact surface between the conductor and the busbar is not exposed in the support portion.
4. The conductive connection structure of the busbar according to any one of claims 1-3, characterized in that, The contact area between the other end face of the conductor and the conductive component is greater than or equal to the cross-sectional area of the main body of the busbar.
5. The conductive connection structure of the busbar according to any one of claims 1-3, characterized in that, The contact area between the outer surface of the conductor and the inner surface of the opening of the busbar is greater than or equal to the cross-sectional area of the main body of the busbar.
6. The conductive connection structure of the busbar according to claim 1, characterized in that, The height of the conductor is greater than or equal to the thickness of the busbar.
7. The conductive connection structure of the busbar according to claim 1, characterized in that, The conductor is cylindrical, and the fastener is a female thread.
8. The conductive connection structure of the busbar according to claim 1, characterized in that, The conductive connection structure is used for conductive connection between the vehicle power battery and the inverter and / or electrical components.
9. The conductive connection structure of the busbar according to claim 1, characterized in that, The conductor is made of copper.
10. The conductive connection structure of the bus according to any one of claims 1-3, characterized in that, The fastener is a bolt.