Conductive busbar assembly and vehicle
By setting a raised contact point in the aluminum busbar assembly, the problem of poor conductivity caused by easy oxidation of aluminum busbars is solved, thereby reducing manufacturing costs and simplifying the process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGZHOU XIAOPENG MOTORS TECH CO LTD
- Filing Date
- 2025-05-14
- Publication Date
- 2026-06-05
AI Technical Summary
Existing aluminum conductive busbar components are prone to oxidation, resulting in poor conductivity. Electroplating is required, which increases costs. Current technologies cannot reduce manufacturing costs while ensuring reliable electrical connections.
An aluminum busbar is used as the first busbar, and the overlapping part of the second busbar is provided with a protrusion that makes point contact with the aluminum busbar. When the fasteners tighten the overlapping part to the connection part, the protrusion pierces the oxide film, thereby achieving a stable electrical connection and avoiding electroplating treatment.
While ensuring the stability of electrical connections, the manufacturing cost of conductive busbar components has been reduced, the manufacturing process has been simplified, and material consumption has been reduced.
Smart Images
Figure CN224328902U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of vehicle technology, and more particularly to a conductive busbar assembly and a vehicle. Background Technology
[0002] With the rapid development of the new energy vehicle industry, the high-voltage electrical system, as one of the core components, directly affects the vehicle's range, safety, and cost-effectiveness through the choice of materials for its conductive busbar components. There are generally two types of materials used for conductive busbar components: copper and aluminum. Copper conductive busbar components have relatively mature conductivity and processing technology, but are more expensive. Aluminum conductive busbar components can reduce costs while still meeting conductivity requirements. However, aluminum is prone to oxidation, usually requiring electroplating, which also increases the manufacturing cost. Utility Model Content
[0003] To address the aforementioned shortcomings in the existing technology, this utility model provides a conductive busbar assembly and a vehicle that can reduce manufacturing costs.
[0004] To address the aforementioned technical problems, in a first aspect, this utility model provides a conductive busbar assembly, comprising:
[0005] The first busbar is an aluminum busbar and includes a first body part and a connecting part. The first body part is used to connect to an electrical circuit assembly.
[0006] The second busbar includes a second body portion and an overlapping portion. The overlapping portion is stacked on the connecting portion along a first direction. The first surface of the overlapping portion is provided with a protrusion. The protrusion abuts against the connecting portion and makes point contact with the connecting portion. The first surface is the surface facing the connecting portion.
[0007] Fastener, the fastener being used to secure the overlapping portion to the connecting portion along the first direction.
[0008] Since the first busbar is made of aluminum, it is prone to oxidation, resulting in an oxide film on its surface. However, the oxide film has poor conductivity. Furthermore, since the first surface of the overlapping part of the second busbar has a protrusion that makes point contact with the connection part of the first busbar, when the fastener secures the overlapping part to the connection part, the protrusion can puncture the oxide film on the connection part, thereby ensuring the stability of the electrical connection between the first and second busbars. Compared to plating an anti-oxidation layer on the first busbar, this reduces the manufacturing cost of the conductive busbar assembly.
[0009] In one possible implementation, the protrusions include a plurality of protrusions, which are evenly distributed on the first surface.
[0010] In one possible implementation, the density of the protrusions on the first surface is d, where d ≥ 1 protrusion / mm. 2 .
[0011] In one possible implementation, the length of the long side of the first surface is d1, d1≥15mm, the length of the wide side of the first surface is d2, d2≥15mm, and the area of the first surface is S, S=d1d2.
[0012] In one possible implementation, the second busbar is an aluminum busbar with an anti-oxidation layer.
[0013] In one possible implementation, the second busbar is a copper busbar.
[0014] In one possible implementation, the surface of the second body portion facing the first busbar is higher than the first surface, and the end face of the second body portion facing the overlapping portion abuts against the end face of the connecting portion.
[0015] In one possible implementation, an insulating layer or a fireproof layer is provided on the first body part.
[0016] In one possible implementation, the connecting portion is provided with a first connecting through hole, and the overlapping portion is provided with a second connecting through hole;
[0017] The fastener includes a screw and a nut, wherein the screw passes through the first connecting through hole and the second connecting through hole in sequence and is fastened to the nut.
[0018] Secondly, this utility model also provides a vehicle, comprising:
[0019] Vehicle body;
[0020] An electrical circuit assembly, which is disposed within the vehicle body, includes a battery module and electrical components;
[0021] The conductive busbar assembly described in the first aspect is wherein one end of the conductive busbar assembly is connected to the battery module and the other end is connected to the electrical device, or both ends of the conductive busbar assembly are respectively connected to the electrical device.
[0022] Compared with the prior art, this application has at least the following beneficial effects:
[0023] In this application, since the first busbar is made of aluminum, it is prone to oxidation, resulting in the formation of an oxide film on its surface. However, the oxide film has poor conductivity. Furthermore, since the first surface of the overlapping portion of the second busbar has a protrusion that makes point contact with the connection portion of the first busbar, when the fastener secures the overlapping portion to the connection portion, the protrusion can puncture the oxide film on the connection portion, thereby ensuring the stability of the electrical connection between the first and second busbars. Compared to plating an anti-oxidation layer on the first busbar, this reduces the manufacturing cost of the conductive busbar assembly. Attached Figure Description
[0024] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the embodiments 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.
[0025] Figure 1 This is a schematic diagram of the structure of the conductive busbar assembly provided in an embodiment of the present utility model;
[0026] Figure 2 A partial exploded view of the conductive busbar assembly provided in an embodiment of this utility model;
[0027] Figure 3 A schematic diagram of the structure of the second busbar from one perspective, provided for an embodiment of this utility model;
[0028] Figure 4 A front view of the second busbar provided in an embodiment of this utility model;
[0029] Figure 5 for Figure 4 Cross-sectional view at point AA;
[0030] Figure 6 A structural schematic diagram of the second busbar from another perspective provided in an embodiment of this utility model;
[0031] Figure 7 A schematic diagram of the structure of the first busbar provided in an embodiment of this utility model;
[0032] Figure 8 for Figure 7 Cross-sectional view at point BB;
[0033] Figure 9 An exploded view of the conductive busbar assembly provided in an embodiment of this utility model;
[0034] Figure 10 A schematic diagram of the vehicle structure provided for an embodiment of this utility model.
[0035] Explanation of reference numerals in the attached figures:
[0036] 100-Conductive busbar assembly;
[0037] 110 - First busbar; 111 - First body part; 1111 - Insulation layer; 1112 - Fireproof layer; 112 - Connecting part; 1121 - First connecting through hole;
[0038] 120 - Second busbar; 121 - Second body part; 122 - Overlapping part; 1221 - First surface; 1222 - Protrusion; 1223 - Second connecting through hole; 123 - Antioxidant layer;
[0039] 130 - Fastener; 131 - Screw; 132 - Nut;
[0040] 200 - Vehicle; 210 - Car body. Detailed Implementation
[0041] 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.
[0042] In this invention, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this invention and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.
[0043] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this utility model according to the specific circumstances.
[0044] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this utility model based on the specific circumstances.
[0045] Furthermore, the terms "first," "second," etc., are primarily used to distinguish different devices, elements, or components (which may be the same or different in specific type and construction), and are not intended to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.
[0046] As described in the background section of this application, with the rapid development of the new energy vehicle industry, the choice of materials for the conductive busbar assemblies in high-voltage electrical circuits, as one of the core components, directly affects the vehicle's range, safety, and cost-effectiveness. Currently, pure copper conductive busbar assemblies remain the mainstream choice for high-voltage electrical circuits due to their excellent conductivity and mature processing technology.
[0047] However, in recent years, pure aluminum conductive busbar components have gradually replaced pure copper conductive busbar components due to their significant cost advantages and lightweight characteristics (density is only 1 / 3 that of copper). Specifically, the pursuit of driving range in new energy vehicles has driven the lightweight design of vehicles, and pure aluminum conductive busbar components can effectively reduce the weight of the vehicle and improve energy efficiency. In addition, since aluminum resources are abundant and the price is lower than that of copper, the large-scale production of pure aluminum conductive busbar components can further reduce costs, which meets the cost reduction needs of the industry chain. Furthermore, with the popularization of 800V and above high-voltage platforms, the current carrying capacity of pure aluminum conductive busbar components can meet the high-power charging requirements through structural optimization. For example, the "busbar-for-line" solution significantly reduces wiring space.
[0048] Of course, pure aluminum conductive busbar assemblies also face new challenges. For example, aluminum oxide layer is easily formed on the surface of aluminum material, and its poor conductivity leads to an increase in the contact resistance of pure aluminum conductive busbar assemblies. Electroplating (such as tin plating or nickel plating) is required to improve the reliability of the electrical connection of the conductive busbar assemblies.
[0049] However, electroplating pure aluminum conductive busbar components will also increase the manufacturing cost of the conductive busbar components.
[0050] Based on this, the present application provides a conductive busbar assembly that can reduce its manufacturing cost while ensuring the reliability of the electrical connection of the conductive busbar assembly.
[0051] The present application will be described in detail below through specific embodiments:
[0052] See Figure 1 , Figure 2 and Figure 3 This application provides a conductive busbar assembly 100, which includes a first busbar 110, a second busbar 120, and a fastener 130. The first busbar 110 is an aluminum busbar and includes a first body portion 111 and a connecting portion 112. The first body portion 111 is used to connect with an electrical circuit assembly. The second busbar 120 includes a second body portion 121 and an overlapping portion 122. The overlapping portion 122 is stacked on the connecting portion 112 along a first direction. The first surface 1221 of the overlapping portion 122 has a protrusion 1222, which abuts against and makes point contact with the connecting portion 112. The first surface 1221 is the surface facing the connecting portion 112. The fastener 130 is used to fasten the overlapping portion 122 to the connecting portion 112 along the first direction.
[0053] It should be noted that the electrical circuit assembly includes battery modules, electrical components, etc. The first busbar 110 can be connected to the battery module or to the electrical components. Similarly, the second busbar 120 can also be connected to the electrical components. For example, the first busbar 110 is connected to the battery module and the second busbar 120 is connected to the electrical components, thus realizing the electrical connection between the electrical components and the battery module.
[0054] In addition, the material of the second busbar 120 can be aluminum, copper or other metals.
[0055] The aforementioned first direction refers to the thickness direction of the first busbar 110 or the second busbar 120, that is... Figure 1 The direction indicated by the X arrow.
[0056] In addition, the first surface 1221 of the aforementioned overlapping portion 122 is provided with a protrusion 1222, which abuts against the connecting portion 112 and makes point contact with the connecting portion 112. It should be understood that the end of the aforementioned protrusion 1222 is a sharp barb, which can pierce the oxide film on the first busbar 110, thereby realizing the electrical connection between the first busbar 110 and the second busbar 120.
[0057] In this embodiment, since the first busbar 110 is made of aluminum, it is prone to oxidation, resulting in an oxide film on its surface. However, the oxide film has poor conductivity. Furthermore, since the first surface 1221 of the overlapping portion 122 of the second busbar 120 is provided with a protrusion 1222, and the protrusion 1222 is in point contact with the connecting portion 112 of the first busbar 110, when the fastener 130 fastens the overlapping portion 122 to the connecting portion 112, the protrusion 1222 can puncture the oxide film on the connecting portion 112, thereby ensuring the stability of the electrical connection between the first busbar 110 and the second busbar 120. Compared with plating an anti-oxidation layer 123 on the first busbar 110, this reduces the manufacturing cost of the conductive busbar assembly 100.
[0058] It should also be noted that the fasteners 130 mentioned above include, but are not limited to, screws 131, bolts, rivets, etc.
[0059] In some possible embodiments, see Figure 3 The protrusions 1222 include multiple protrusions, which are evenly distributed on the first surface 1221.
[0060] Among them, "multiple" refers to two or more quantities, such as 8, 10, 20, etc.
[0061] Since multiple protrusions 1222 are evenly distributed on the first surface 1221, the contact area of the electrical connection between the first busbar 110 and the second busbar 120 can be increased, thereby effectively reducing the contact resistance between the first busbar 110 and the second busbar 120.
[0062] In some possible embodiments, the density of the protrusions 1222 distributed on the first surface 1221 is d, where d ≥ 1 protrusion / mm 2 .
[0063] If the distribution of protrusions 1222 on the first surface 1221 is sparse, it will affect the contact area of the electrical connection between the first busbar 110 and the second busbar 120, thereby increasing the contact resistance between the first busbar 110 and the second busbar 120. Based on this, in this embodiment, the density of protrusions 1222 on the first surface 1221 is not less than 1 per square millimeter. In other words, at least one protrusion 1222 is provided on the first surface 1221 per square millimeter.
[0064] In this way, the contact resistance between the first busbar 110 and the second busbar 120 can be reduced while ensuring a stable electrical connection between the first busbar 110 and the second busbar 120.
[0065] In some possible embodiments, see Figure 4The length of the long side of the first surface 1221 is d1, d1≥15mm, the length of the wide side of the first surface 1221 is d2, d2≥15mm, and the area of the first surface 1221 is S, S=d1d2.
[0066] In this embodiment, the first surface 1221 is considered to be a regular shape, such as a rectangle or a square. Of course, in some other embodiments, the first surface 1221 can also be other shapes, such as the center of a regular shape, a triangle, a trapezoid, etc., or an irregular shape such as a polygon.
[0067] In this embodiment, if the length of the first surface 1221 is less than 15mm and the width of the first surface 1221 is less than 15mm, it indicates that the area of the first surface 1221 is small. On the one hand, this reduces the contact area between the connecting portion 112 and the overlapping portion 122. On the other hand, it reduces the number of protrusions 1222 provided on the overlapping portion 122, thereby reducing the electrical connection area between the overlapping portion 122 and the connecting portion 112, and thus increasing the contact resistance between the overlapping portion 122 and the connecting portion 112. Based on this, the length of the first surface 1221 is greater than or equal to 15mm and the width of the first surface 1221 is greater than or equal to 15mm. In this way, the contact area between the overlapping portion 122 and the connecting portion 112 can be guaranteed, thereby ensuring the connection strength between the overlapping portion 122 and the connecting portion 112, and the electrical connection area between the overlapping portion 122 and the connecting portion 112 can also be guaranteed, thus ensuring the electrical connection effect between the overlapping portion 122 and the connecting portion 112.
[0068] In some possible embodiments, see Figure 4 and Figure 5 The second busbar 120 is an aluminum busbar, and an anti-oxidation layer 123 is provided on the second busbar 120.
[0069] When the second busbar 120 is an aluminum busbar, it is prone to oxidation, forming an oxide film on its surface. This oxide film has weak conductivity, which affects the conductivity between the first busbar 110 and the second busbar 120. Therefore, it is necessary to plate an anti-oxidation layer 123 onto the aluminum busbar 120 to prevent the surface of the second busbar 120 from being oxidized, thereby ensuring the effectiveness of the electrical connection between the second busbar 120 and the first busbar 110.
[0070] Since the second busbar 120 is made of aluminum, an anti-oxidation layer 123 is provided on the second busbar 120. Therefore, the conductivity of the surface of the second busbar 120 is not affected. Thus, when the protrusion 1222 on the overlapping part 122 abuts against the connecting part 112 and punctures the oxide film on the connecting part 112, the protrusion 1222 can still be electrically connected to the connecting part 112, ensuring the effect of electrical connection between the two.
[0071] Furthermore, aluminum is relatively inexpensive and lightweight, thus reducing the weight of the conductive busbar assembly 100 itself while reducing its size.
[0072] In some possible embodiments, the second busbar 120 is a copper busbar.
[0073] Since copper is not easily oxidized, when the second busbar 120 is a copper busbar, there is no need to plate an anti-oxidation layer 123 on the surface of the second busbar 120. In addition, copper is relatively hard, so the protrusions 1222 on the overlapping part 122 can more easily pierce the oxide film on the connecting part 112, thereby improving the electrical connection effect between the overlapping part 122 and the connecting part 112.
[0074] Furthermore, since copper has good anti-oxidation properties, there is no need to set an anti-oxidation layer 123 on the surface of the second busbar 120, which simplifies the manufacturing process of the second busbar 120 and thus simplifies the preparation process of the conductive busbar assembly 100.
[0075] In some possible embodiments, see Figure 6 and Figure 7 The surface of the second body portion 121 facing the first busbar 110 is higher than the first surface 1221, and the end face of the second body portion 121 facing the overlapping portion 122 abuts against the end face of the connecting portion 112.
[0076] Therefore, the end face of the second body part 121 facing the first busbar 110 can pre-position the overlapping part 122 when the overlapping part 122 and the connecting part 112 are assembled, thereby improving the accuracy of the assembly of the overlapping part 122 and the connecting part 112, and thus improving the efficiency of the assembly of the first busbar 110 and the second busbar 120.
[0077] In some possible embodiments, see Figure 8 An insulating layer 1111 or a fireproof layer 1112 is provided on the first body part 111.
[0078] Since the first body part 111 is connected to the battery module or electrical components, when the length of the first body part 111 is long, it is easy for it to become electrically connected to other components in the vehicle 200, thereby affecting the normal operation of the vehicle 200. Therefore, it is necessary to prevent such a situation from occurring. Based on this, an insulating layer 1111 is provided on the first body part 111 to prevent the first body part 111 from becoming electrically connected to other components in the vehicle 200, thereby ensuring the normal operation of the vehicle 200.
[0079] In addition, while the first body part 111 conducts electricity, it will generate heat, which will affect the electrical components near the first component. Based on this, a fireproof layer 1112 is provided on the first body part 111 to insulate and prevent the first body part 111 from being affected by the electrical components near the first body part 111.
[0080] In some possible embodiments, see Figure 9 The connecting part 112 is provided with a first connecting through hole 1121, and the overlapping part 122 is provided with a second connecting through hole 1223; the fastener 130 includes a screw 131 and a nut 132, the screw 131 passes through the first connecting through hole 1121 and the second connecting through hole 1223 in sequence and is fastened with the nut 132.
[0081] Therefore, the connection between the connecting part 112 and the overlapping part 122 is detachable, which improves the convenience of replacing the connecting part 112 and the overlapping part 122 compared to the welding connection between the overlapping part 122 and the connecting part 112.
[0082] Of course, in some other embodiments, the connecting part 112 for the overlapping part 122 can also be a riveting, snap-fit or other connection method.
[0083] See Figure 10 This application also provides a vehicle 200, which includes a vehicle body 210, an electrical circuit assembly and a conductive busbar assembly 100. The electrical circuit assembly is disposed in the vehicle body 210 and includes a battery module and electrical components. In the above embodiment, one end of the conductive busbar assembly 100 is connected to the battery module and the other end is connected to the electrical components, or the conductive busbar assembly 100 is connected to the electrical components respectively.
[0084] The conductive busbar assembly 100 in this embodiment may have the same structure as any of the conductive busbar assemblies 100 in the above embodiments and may bring the same or similar beneficial effects. For details, please refer to the description in the above embodiments. This embodiment will not be repeated here.
[0085] It should be noted that the electrical circuit assembly includes multiple electrical components. It should be understood that the conductive busbar assembly 100 is connected to each electrical component. One end of the conductive busbar assembly 100 is connected to one electrical component, and the other end is connected to another electrical component.
[0086] Since the vehicle 200 uses the conductive busbar assembly 100 in the above embodiment, the manufacturing cost of the vehicle 200 can be reduced while maintaining the normal operation of the vehicle 200.
[0087] Among them, the aforementioned vehicles 200 include pure electric vehicles, plug-in hybrid electric vehicles, range-extended electric vehicles, fuel cell vehicles, etc.
[0088] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.
Claims
1. A conductive busbar assembly, characterized in that, include: The first busbar is an aluminum busbar and includes a first body part and a connecting part. The first body part is used to connect to an electrical circuit assembly. The second busbar includes a second body portion and an overlapping portion. The overlapping portion is stacked on the connecting portion along a first direction. The first surface of the overlapping portion is provided with a protrusion. The protrusion abuts against the connecting portion and makes point contact with the connecting portion. The first surface is the surface facing the connecting portion. Fastener, the fastener being used to secure the overlapping portion to the connecting portion along the first direction.
2. The conductive busbar assembly according to claim 1, characterized in that, The protrusions include a plurality of protrusions, which are evenly distributed on the first surface.
3. The conductive busbar assembly according to claim 2, characterized in that, The density of the protrusions on the first surface is d, where d ≥ 1 protrusion / mm. 2 .
4. The conductive busbar assembly according to claim 1, characterized in that, The length of the first surface is d1, d1≥15mm, the length of the width of the first surface is d2, d2≥15mm, and the area of the first surface is S, S=d1d2.
5. The conductive busbar assembly according to claim 1, characterized in that, The second busbar is an aluminum busbar, and an anti-oxidation layer is provided on the second busbar.
6. The conductive busbar assembly according to claim 1, characterized in that, The second busbar is a copper busbar.
7. The conductive busbar assembly according to any one of claims 1-6, characterized in that, The surface of the second body portion facing the first busbar is higher than the first surface, and the end face of the second body portion facing the overlapping portion abuts against the end face of the connecting portion.
8. The conductive busbar assembly according to any one of claims 1-6, characterized in that, An insulating layer or a fireproof layer is provided on the first body part.
9. The conductive busbar assembly according to any one of claims 1-6, characterized in that, The connecting part is provided with a first connecting through hole, and the overlapping part is provided with a second connecting through hole; The fastener includes a screw and a nut, wherein the screw passes through the first connecting through hole and the second connecting through hole in sequence and is fastened to the nut.
10. A vehicle, characterized in that, include: Vehicle body; An electrical circuit assembly, which is disposed within the vehicle body, includes a battery module and electrical components; The conductive busbar assembly according to any one of claims 1-9, wherein one end of the conductive busbar assembly is connected to the battery module and the other end is connected to the electrical device, or both ends of the conductive busbar assembly are respectively connected to the electrical device.