Composite material protective busbar

Abstract

This utility model relates to the field of copper-aluminum busbar technology, specifically a composite material protective busbar, comprising: a busbar body, a first protective layer, and a second protective layer. The first protective layer includes a first polymer layer, a PI layer, and a second polymer layer, with the second protective layer covering the outside of the first protective layer. The PI layer is formed by wrapping a strip around the busbar body in a first direction, with the first and second polymer layers formed on opposite sides of the PI layer. The PI layer is formed by spirally wrapping the strip along the length of the busbar to ensure the continuity of the insulation layer. The polymer layers on both sides are tightly bonded to the PI layer in the middle, blocking external corrosion. The second protective layer serves as an outer layer of protection, enhancing overall weather resistance and wear resistance. The double-layer protection enables the busbar to operate stably in high-temperature environments. The elastic properties of the polymer layers buffer external impacts, prevent mechanical damage, ensure uniform coverage, extend service life, and are highly practical.

Description

Technical Field

[0001] This utility model relates to the field of copper-aluminum busbar technology, specifically to a composite material protective busbar. Background Technology

[0002] Copper busbars, also known as aluminum busbars, are long first conductor layers made of copper or aluminum with a rectangular or chamfered (rounded) rectangular cross-section. Copper-aluminum busbars are high-strength, corrosion-resistant metal conductors made of copper and aluminum through a high-pressure torsion rolling process, and are widely used in power systems.

[0003] Existing copper-aluminum busbars typically use fluoropolymers and polyimide to protect the copper-aluminum busbar body with composite materials. However, these materials are usually wrapped in a single layer, which cannot maintain good insulation and protection performance when the copper-aluminum busbar body is bent or under high temperature or flame, resulting in a short service life and poor safety. Utility Model Content

[0004] To address the aforementioned problems, this utility model provides a composite material protective busbar, which solves the problem that existing copper-aluminum busbars typically use fluoropolymers and polyimide to protect the copper-aluminum busbar body. However, these materials are usually wrapped in a single layer, and cannot maintain good insulation and protective performance when the copper-aluminum busbar body is bent or under high temperature or flame conditions, resulting in a short service life and poor safety.

[0005] The technical solution adopted by this utility model is as follows: it includes an electric bus body and a first protective layer and a second protective layer disposed outside the electric bus body. The first protective layer includes a first polymer layer, a PI layer and a second polymer layer disposed sequentially. The second protective layer covers the outside of the first protective layer. The PI layer is formed by wrapping a strip around the electric bus body along a first direction. The first polymer layer and the second polymer layer are respectively formed on two sides of the PI layer.

[0006] A further improvement to the above scheme is that the busbar body is a copper busbar, an aluminum busbar, or a copper-aluminum composite busbar, used for battery conductivity.

[0007] A further improvement to the above scheme is that both the first polymer layer and the second polymer layer are fluoropolymers.

[0008] A further improvement to the above scheme is that the thickness of the first polymer layer is 3μm-100μm.

[0009] A further improvement to the above scheme is that the thickness of the second polymer layer is 3μm-100μm.

[0010] A further improvement to the above scheme is that the PI layer includes a first PI layer and a second PI layer. The first PI layer is formed by wrapping a strip around the busbar body in a first direction, and the second PI layer is formed by wrapping a strip around the busbar body in a second direction. The first direction and the second direction are the relative directions of the length of the busbar body.

[0011] A further improvement to the above solution is that the second protective layer is connected to the outside of the first protective layer by wrapping or bonding.

[0012] A further improvement to the above scheme is that the second protective layer is a Teflon layer.

[0013] The beneficial effects of this utility model are:

[0014] Compared to existing copper-aluminum busbars, the PI layer of this invention is formed by spirally wrapping a strip along the length of the busbar, ensuring the continuity of the insulation layer and enhancing mechanical strength. The polymer layers on both sides are tightly bonded to the PI layer in the middle, effectively blocking the intrusion of external moisture and corrosive media. The second protective layer, as an outer layer of protection, further enhances the weather resistance and wear resistance of the overall structure. The double-layer protection enables the busbar to work stably in high-temperature environments. The elastic properties of the polymer layer can buffer external impacts, prevent mechanical damage, improve insulation performance and chemical corrosion resistance, ensure uniform coverage, extend service life, and make it highly practical. Attached Figure Description

[0015] Figure 1 This is a perspective view of the composite material protective electric busbar of this utility model;

[0016] Figure 2 This is a schematic diagram of the composite material protective electric busbar of this utility model.

[0017] Figure labeling: Electric busbar body 10;

[0018] First protective layer 20, first polymer layer 21, PI layer 22, second polymer layer 23;

[0019] Second protective layer 30. Detailed Implementation

[0020] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0021] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0023] like Figures 1-2 As shown in the embodiment of this utility model, a composite material protective busbar includes: a busbar body 10 and a first protective layer 20 and a second protective layer 30 disposed outside the busbar body 10. The first protective layer 20 includes a first polymer layer 21, a PI layer 22 and a second polymer layer 23 disposed sequentially. The second protective layer 30 covers the outside of the first protective layer 20. The PI layer 22 is formed by wrapping a strip around the busbar body 10 in a first direction. The first polymer layer 21 and the second polymer layer 23 are respectively formed on two sides of the PI layer 22. In this embodiment, the PI layer 22 is formed by spirally wrapping a strip along the length of the busbar, ensuring the continuity of the insulation layer and enhancing mechanical strength. The polymer layers on both sides are tightly bonded to the PI layer 22 in the middle, effectively blocking the intrusion of external moisture and corrosive media. The second protective layer 30 serves as an outer layer of protection, further enhancing the weather resistance and wear resistance of the overall structure. The double-layer protection enables the busbar to work stably in high-temperature environments. The elastic properties of the polymer layer can buffer external impacts, prevent mechanical damage, improve insulation performance and chemical corrosion resistance, ensure uniform coverage, extend service life, and enhance practicality.

[0024] The battery pack body 10 is made of copper, aluminum, or a copper-aluminum composite material and is used for battery conductivity. In this embodiment, by using copper, aluminum, or a copper-aluminum composite material as the conductive material for the battery pack body 10, the conductivity requirements of the battery system can be effectively met. Copper has excellent conductivity and corrosion resistance, while aluminum has advantages in lightweight and cost. The copper-aluminum composite material combines the advantages of both, reducing overall weight and production cost while ensuring conductivity.

[0025] Both the first polymer layer 21 and the second polymer layer 23 are fluoropolymers. In this embodiment, by using fluoropolymer materials for both the first polymer layer 21 and the second polymer layer 23, the protective performance of the composite material can be significantly improved. Fluoropolymers have excellent chemical corrosion resistance, weather resistance, and insulation properties, thus extending the service life of the busbar.

[0026] The thickness of the first polymer layer 21 ranges from 3 μm to 100 μm. In this embodiment, a 3 μm layer thickness enables a lightweight design, making it suitable for weight-sensitive applications; while a thicker 100 μm layer provides superior wear resistance and impact protection. This thickness range has been repeatedly verified through experiments to balance protective performance and material cost, ensuring long-term stable operation of the power bus under complex working conditions.

[0027] The thickness of the second polymer layer 23 is 3μm-100μm. In this embodiment, the 3μm to 100μm second polymer layer 23 ensures that the polymer layer has sufficient mechanical strength and wear resistance, while avoiding the problem of reduced material flexibility due to excessive thickness; it can ensure that the material maintains good electrical conductivity while providing basic protection; and the 100μm thick layer can significantly enhance the protective effects such as impact resistance and corrosion resistance.

[0028] The second protective layer 30 is externally connected to the first protective layer 20 by wrapping or bonding. In this embodiment, the wrapping or bonding connection between the second protective layer 30 and the first protective layer 20 enhances the overall protective performance of the busbar, providing a double protective barrier for the internal conductors and effectively resisting external mechanical damage and environmental influences. The wrapping or bonding connection process ensures a tight bond between the protective layers, avoids the risk of interlayer separation, and improves structural stability.

[0029] The second protective layer 30 is a Teflon layer. In this embodiment, the use of Teflon material in the second protective layer 30 can significantly improve the overall protective performance of the composite busbar; Teflon has excellent high temperature resistance and can remain stable in the range of -200℃ to 260℃, effectively preventing material aging of the busbar due to temperature changes, reducing mechanical wear, and extending the service life of the busbar.

[0030] A composite material protective busbar includes: a busbar body 10 and a first protective layer 20 and a second protective layer 30 disposed outside the busbar body 10. The first protective layer 20 includes a first polymer layer 21, a PI layer 22 and a second polymer layer 23 disposed sequentially. The second protective layer 30 covers the outside of the first protective layer 20. The PI layer 22 is formed by wrapping a strip around the busbar body 10 in a first direction. The first polymer layer 21 and the second polymer layer 23 are respectively formed on two sides of the PI layer 22. In this embodiment, the PI layer 22 is formed by spirally wrapping a strip along the length of the busbar, ensuring the continuity of the insulation layer and enhancing mechanical strength. The polymer layers on both sides are tightly bonded to the PI layer 22 in the middle, effectively blocking the intrusion of external moisture and corrosive media. The second protective layer 30 serves as an outer layer of protection, further enhancing the weather resistance and wear resistance of the overall structure. The double-layer protection enables the busbar to work stably in high-temperature environments. The elastic properties of the polymer layer can buffer external impacts, prevent mechanical damage, improve insulation performance and chemical corrosion resistance, ensure uniform coverage, extend service life, and enhance practicality.

[0031] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A composite material shielded electrical raceway characterized by, include: The electric busbar body includes a first protective layer and a second protective layer disposed outside the electric busbar body. The first protective layer includes a first polymer layer, a PI layer and a second polymer layer disposed sequentially. The second protective layer covers the outside of the first protective layer. The PI layer is formed by wrapping a strip around the electric busbar body in a first direction. The first polymer layer and the second polymer layer are respectively formed on two sides of the PI layer.

2. The composite material protective busbar according to claim 1, characterized in that: The busbar body is a copper busbar, an aluminum busbar, or a copper-aluminum composite busbar, used for battery conductivity.

3. The composite armored electrical raceway of claim 1, wherein: Both the first polymer layer and the second polymer layer are fluoropolymers.

4. The composite armored electrical raceway of claim 3, wherein: The thickness of the first polymer layer is 3μm-100μm.

5. The composite armored electrical raceway of claim 4, wherein: The thickness of the second polymer layer is 3μm-100μm.

6. The composite armored electrical raceway of claim 1, wherein: The PI layer includes a first PI layer and a second PI layer. The first PI layer is formed by wrapping a strip around the busbar body in a first direction, and the second PI layer is formed by wrapping a strip around the busbar body in a second direction. The first direction and the second direction are the length-to-length directions of the busbar body.

7. The composite shielded electrical raceway of claim 6, wherein: The second protective layer is connected to the outside of the first protective layer by wrapping or bonding.

8. The composite material shielded electrical raceway of claim 7, wherein: The second protective layer is a Teflon layer.

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