Corrosion-resistant power board current guide aluminum busbar

Abstract

This utility model relates to the field of power electronic equipment technology and discloses an anti-corrosion power board current-conducting aluminum busbar, including an aluminum busbar body. Two symmetrical connection ports are opened at both ends of the aluminum busbar body along its length. Each connection port is a circular through-hole penetrating the upper and lower end faces of the aluminum busbar body. An aluminum busbar substrate is embedded and fixed inside the aluminum busbar body. An anti-corrosion mechanism is provided on the outer surface of the aluminum busbar substrate, and a connection protection mechanism is provided inside the connection ports. The anti-corrosion mechanism includes a ceramic layer and an anti-corrosion coating. The ceramic layer is a micro-arc oxidation ceramic layer, formed on the outer surface of the aluminum busbar substrate through a micro-arc oxidation process. In this utility model, the micro-arc oxidation on the outer surface of the aluminum busbar substrate forms a ceramic layer with uniform micropores, increasing bonding strength and initially isolating corrosive media. The sprayed epoxy resin anti-corrosion coating fills the micropores and covers the ceramic layer; the two layers work together to slow corrosion without affecting conductivity, ensuring stable current conduction of the aluminum busbar.

Description

Technical Field

[0001] This utility model relates to the field of power electronic equipment technology, and in particular to corrosion-resistant power board current-conducting aluminum busbars. Background Technology

[0002] The power board is the core functional circuit board in power electronic equipment (such as inverters, frequency converters, UPS power supplies, etc.), mainly undertaking the key tasks of power conversion, power transmission, and control. Structurally, it integrates power semiconductor devices (such as IGBTs, MOSFETs, etc.), drive circuits, protection circuits, and connection terminals. During operation, it efficiently processes the input electrical energy (such as converting DC to AC, or regulating voltage and frequency) before outputting it to meet the needs of different electrical devices. In the field of new energy (such as photovoltaic inverters and energy storage systems), the performance of the power board directly determines the power density, conversion efficiency, and operational stability of the equipment. It also requires excellent heat dissipation design and electromagnetic compatibility to adapt to high-power, long-term operating conditions.

[0003] The aluminum busbar is a key current-conducting component in power boards, widely used in power electronic equipment such as inverters and frequency converters. Because power boards often operate in humid, dusty, or corrosive environments, the aluminum busbar is susceptible to corrosion, leading to corrosion spots and peeling on the surface. This damages the busbar's conductivity, increases current-conducting resistance, and causes localized overheating. In severe cases, it can cause power board failure and affect the normal operation of the entire power electronic equipment.

[0004] However, in the existing technology, some current-guiding aluminum busbars are mostly treated with simple anodizing, which has limited corrosion resistance and is difficult to adapt to harsh working environments. Therefore, corrosion-resistant power board current-guiding aluminum busbars are proposed to solve the above problems. Utility Model Content

[0005] To overcome the above deficiencies, this utility model provides a corrosion-resistant power board current-guiding aluminum busbar, which aims to improve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: The corrosion-resistant power board current guide aluminum busbar includes an aluminum busbar body. Two connection ports are symmetrically opened at both ends of the aluminum busbar body along the length direction. The connection ports are circular through holes that penetrate the upper and lower end faces of the aluminum busbar body. An aluminum busbar substrate is embedded and fixed inside the aluminum busbar body. An anti-corrosion mechanism is provided on the outer surface of the aluminum busbar substrate. A connection protection mechanism is provided inside the connection port. The anti-corrosion mechanism includes a ceramic layer and an anti-corrosion coating. The ceramic layer is a micro-arc oxidation ceramic layer, which is formed on the outer surface of the aluminum substrate through a micro-arc oxidation process. The thickness is 8-15μm, and the surface forms a uniform microporous structure. The anti-corrosion coating is an epoxy resin anti-corrosion coating, which is filled into the micropores and surface of the ceramic layer through a spray curing process. The filling thickness is 3-6μm. As a further description of the above technical solution: The top of the aluminum busbar body is provided with a number of heat dissipation fins spaced apart along the length direction. The heat dissipation fins are arranged in a more dense manner closer to the connection port. The front and rear sides of the aluminum busbar body are provided with reinforcing ribs, and the material of the reinforcing ribs is 6061 aluminum alloy. As a further description of the above technical solution: The bottom left and right sides of the aluminum busbar body are provided with positioning grooves, and the cross-section is T-shaped; As a further description of the above technical solution: The connection protection mechanism includes an anti-corrosion layer and a conductive anti-loosening layer. The anti-corrosion layer is fixedly installed on the inner wall of the connection port by plasma spraying process, and has a thickness of 5-8μm. The inner wall of the anti-corrosion layer has a spiral groove along the circumferential direction. The conductive anti-loosening layer is filled in the spiral groove, and the inner wall of the conductive anti-loosening layer is flush with the inner wall of the anti-corrosion layer. As a further description of the above technical solution: The anti-corrosion layer is made of a nickel-based alloy with a nickel content of not less than 90%, and the conductive anti-loosening layer is made of silver-based conductive anti-loosening adhesive. As a further description of the above technical solution: A gasket is provided on the top side of the connection port. The gasket has an annular opening structure and is coaxially arranged with the connection port. The gasket is made of nitrile rubber. As a further description of the above technical solution: The aluminum busbar substrate is made of 1060 pure aluminum with a purity of not less than 99.6%, and the cross-sectional area of ​​the aluminum busbar substrate accounts for 70% to 80% of the cross-sectional area of ​​the aluminum busbar body.

[0007] This utility model has the following beneficial effects: 1. In this invention, a ceramic layer formed on the outer surface of the aluminum busbar substrate through a micro-arc oxidation process has uniform micropores on its surface, which enhance the adhesion to the subsequent anti-corrosion coating and initially block air and moisture from contacting the aluminum busbar substrate. Then, an epoxy resin anti-corrosion coating is filled through a spray curing process, filling the micropores and covering the ceramic layer surface, further isolating dust and acidic gases. This dual-layer anti-corrosion structure works synergistically to effectively slow down the corrosion rate of the aluminum busbar substrate without affecting its conductivity, enabling the aluminum busbar to maintain stable flow conduction even under complex operating conditions.

[0008] 2. In this invention, a nickel-based alloy anti-corrosion layer is applied to the inner wall of the connector by plasma spraying to prevent crevice corrosion and oxidation of the inner wall metal. The silver-based conductive anti-loosening layer filling the spiral groove of the inner wall ensures low-resistance contact between the aluminum busbar and the bolt through its silver-based composition, and also prevents bolt vibration and loosening through the curing properties of the anti-loosening adhesive. The annular open nitrile rubber gasket on the top side of the connector forms a sealing barrier after the bolt is tightened, preventing moisture and dust from entering. These three elements work together to comprehensively improve the protective performance of the connector, preventing corrosion and increased contact resistance, and ensuring the long-term reliability of the connection between the aluminum busbar and external components. Attached Figure Description

[0009] Figure 1 This is a perspective view of the corrosion-resistant power plate current-guiding aluminum busbar proposed in this utility model; Figure 2 This is a schematic diagram of the aluminum busbar substrate of the corrosion-resistant power plate current-guiding aluminum busbar proposed in this utility model; Figure 3 for Figure 2 Enlarged view of point A in the middle.

[0010] Legend: 1. Aluminum busbar body; 2. Connecting port; 3. Aluminum busbar base; 4. Ceramic layer; 5. Anti-corrosion coating; 6. Heat dissipation fins; 7. Positioning groove; 8. Reinforcing rib; 9. Anti-corrosion layer; 10. Conductive and anti-loosening layer; 11. Gasket. Detailed Implementation

[0011] 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.

[0012] Reference Figure 1 , Figure 2 and Figure 3 This utility model provides an embodiment of a corrosion-resistant power board flow guide aluminum busbar, including an aluminum busbar body 1, which is the basic frame of the entire flow guide aluminum busbar. Two connection ports 2 are symmetrically opened at both ends of the aluminum busbar body 1 along the length direction. The connection ports 2 are circular through holes that penetrate the upper and lower end faces of the aluminum busbar body 1 and serve as connection channels between the aluminum busbar and external components. An aluminum busbar base 3 is embedded and fixed inside the aluminum busbar body 1. The aluminum busbar base 3 is made of 1060 pure aluminum with a purity of not less than 99.6%. The cross-sectional area of ​​the aluminum busbar base 3 accounts for 70% to 80% of the cross-sectional area of ​​the aluminum busbar body 1 and is used to ensure the flow guiding performance of the aluminum busbar. An anti-corrosion mechanism is provided on the outer surface of the aluminum busbar base 3, and a connection protection mechanism is provided inside the connection ports 2. The anti-corrosion mechanism includes a ceramic layer 4 and an anti-corrosion coating 5. The ceramic layer 4 is a micro-arc oxidation ceramic layer, which is formed on the outer surface of the aluminum busbar substrate 3 through a micro-arc oxidation process. The thickness is 8-15μm, and the surface forms a uniform microporous structure. The anti-corrosion coating 5 is an epoxy resin anti-corrosion coating, which is filled into the micropores and surface of the ceramic layer 4 through a spray curing process. The filling thickness is 3-6μm. The micropores can enhance the bonding force with the anti-corrosion coating 5, prevent the coating from falling off, and at the same time, it has strong corrosion resistance and can initially block the contact between air and moisture and the aluminum busbar substrate 3, thus delaying corrosion. The top of the aluminum busbar body 1 is provided with several heat dissipation fins 6 at intervals along the length direction. The heat dissipation fins 6 are arranged more densely closer to the connection port 2. The area around the connection port 2 is prone to high temperature. The dense fins can quickly dissipate heat and ensure the stable working temperature of the aluminum busbar. The front and rear sides of the aluminum busbar body 1 are provided with reinforcing ribs 8. The reinforcing ribs 8 are made of 6061 aluminum alloy. 6061 aluminum alloy has high strength and can enhance the overall structural strength of the aluminum busbar, prevent the aluminum busbar from deforming during installation, flow, or thermal expansion and contraction, and ensure the structural stability of the aluminum busbar. The bottom left and right sides of the aluminum busbar body 1 are provided with positioning grooves 7. The cross-section is T-shaped and can be precisely matched with the positioning protrusions on the power board to ensure the accurate position of the aluminum busbar during installation and avoid poor connection caused by installation misalignment. The connection protection mechanism includes an anti-corrosion layer 9 and a conductive anti-loosening layer 10. The anti-corrosion layer 9 is fixedly applied to the inner wall of the connection port 2 by plasma spraying, with a thickness of 5-8 μm. The material of the anti-corrosion layer 9 is a nickel-based alloy with a nickel content of not less than 90%. The nickel-based alloy has excellent corrosion resistance and adhesion, which can prevent crevice corrosion caused by bolt connection on the inner wall of the connection port 2 and avoid the metal oxidation of the inner wall affecting the conductivity. The conductive anti-loosening layer 10 is made of silver-based conductive anti-loosening adhesive. The inner wall of the anti-corrosion layer 9 has a spiral groove along the circumference, and the conductive anti-loosening layer 10 fills the spiral groove. The inner wall of the conductive anti-loosening layer 10 is flush with the inner wall of the anti-corrosion layer 9, which is used to achieve corrosion protection and anti-loosening at the connection. The silver-based composition ensures low resistance contact between the aluminum busbar and the bolt, ensuring stable current transmission. After the anti-loosening adhesive is cured, it can prevent the bolt from loosening due to power board vibration, thus combining conductivity and anti-loosening functions. A gasket 11 is provided on the top side of the connection port 2. The gasket 11 has an annular opening structure and is coaxially arranged with the connection port 2. The gasket 11 is made of nitrile rubber. Nitrile rubber has good sealing performance. When the bolt is tightened, the gasket 11 fits tightly against the bolt washer and the surface of the aluminum strip body 1 to form a sealing barrier, preventing moisture and dust from entering from the top of the connection port 2 and improving the sealing performance of the connection part.

[0013] Working principle: The aluminum busbar body 1 is embedded with an aluminum busbar substrate 3, which is 1060 pure aluminum with a purity of ≥99.6% and accounts for 70% to 80% of the cross-section. Its outer surface is formed with an 8-15μm thick ceramic layer 4 through a micro-arc oxidation process. The uniform microporous structure on the surface of the ceramic layer 4 can enhance the adhesion with the subsequent anti-corrosion coating and prevent the coating from falling off. On the other hand, it has excellent corrosion resistance and can initially block the direct contact between air and moisture and the aluminum busbar substrate 3. Subsequently, through a spray curing process, a 3-6μm thick epoxy resin anti-corrosion coating 5 is filled into the micropores and surface of the ceramic layer 4. The epoxy resin anti-corrosion coating 5 can not only fill the micropores to form a dense protective layer, but also cover the entire surface of the ceramic layer 4, further isolating dust, acidic gases and other corrosive media. The dual protective structure works synergistically to effectively slow down the corrosion rate of the aluminum busbar substrate 3, while not affecting the high conductivity of 1060 pure aluminum, ensuring the flow conduction efficiency of the aluminum busbar. The inner wall of connector 2 is coated with a 5-8μm thick nickel-based alloy anti-corrosion layer 9 with a nickel content ≥90% using a plasma spraying process. The high corrosion resistance of the nickel-based alloy anti-corrosion layer 9 prevents crevice corrosion caused by bolt connections on the inner wall of connector 2, avoiding metal oxidation that could affect conductivity. The spiral grooves on the inner wall of the nickel-based alloy anti-corrosion layer 9 are filled with a silver-based conductive anti-loosening layer 10. The inner wall of the silver-based conductive anti-loosening layer 10 is flush with the nickel-based alloy anti-corrosion layer 9. This ensures low-resistance contact between the aluminum busbar and the connecting bolts through the silver-based composition, ensuring stable current transmission. It also prevents the bolts from loosening due to power board vibration by utilizing the curing properties of the anti-loosening adhesive, maintaining connection reliability. At the same time, the annular open nitrile rubber gasket 11 on the top side of connector 2 is coaxial with connector 2. When the bolts are tightened, it will tightly adhere to the bolt washer and the surface of the aluminum busbar body 1, forming a sealing barrier to prevent moisture and dust from entering from the top of connector 2. Together with the nickel-based alloy anti-corrosion layer 9 and the silver-based conductive anti-loosening layer 10, the overall protective performance of connector 2 is improved.

[0014] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. Anti-corrosion power plate aluminum bar, comprising aluminum bar body (1), characterized in that: The aluminum busbar body (1) has two symmetrical connection ports (2) at both ends along the length direction. The connection port (2) is a circular through hole that penetrates the upper and lower end faces of the aluminum busbar body (1). An aluminum busbar base (3) is embedded and fixed inside the aluminum busbar body (1). An anti-corrosion mechanism is provided on the outer surface of the aluminum busbar base (3). A connection protection mechanism is provided inside the connection port (2). The anti-corrosion mechanism includes a ceramic layer (4) and an anti-corrosion coating (5). The ceramic layer (4) is a micro-arc oxidation ceramic layer, which is formed on the outer surface of the aluminum busbar substrate (3) by micro-arc oxidation process, with a thickness of 8-15μm and a uniform microporous structure on the surface. The anti-corrosion coating (5) is an epoxy resin anti-corrosion coating, which is filled in the micropores and surface of the ceramic layer (4) by spray curing process, with a filling thickness of 3-6μm. The top of the aluminum busbar body (1) is provided with a number of heat dissipation fins (6) spaced along the length direction. The heat dissipation fins (6) are arranged in a denser manner closer to the connection port (2). The front and rear sides of the aluminum busbar body (1) are provided with reinforcing ribs (8). The material of the reinforcing ribs (8) is 6061 aluminum alloy. The bottom left and right sides of the aluminum busbar body (1) are provided with positioning grooves (7), and the cross section is T-shaped; The connection protection mechanism includes an anti-corrosion layer (9) and a conductive anti-loosening layer (10). The anti-corrosion layer (9) is fixedly installed on the inner wall of the connection port (2) by plasma spraying process, and has a thickness of 5-8μm. The inner wall of the anti-corrosion layer (9) is provided with a spiral groove along the circumferential direction. The conductive anti-loosening layer (10) is filled in the spiral groove, and the inner wall of the conductive anti-loosening layer (10) is flush with the inner wall of the anti-corrosion layer (9). A pad (11) is provided on the top side of the connection port (2). The pad (11) has an annular opening structure and is coaxially arranged with the connection port (2). The material of the pad (11) is nitrile rubber.

2. The corrosion resistant power panel bus bar of claim 1, wherein: The anti-corrosion layer (9) is made of nickel-based alloy, and the conductive anti-loosening layer (10) is made of silver-based conductive anti-loosening adhesive.

3. The corrosion-resistant power board current-guiding aluminum busbar according to claim 1, characterized in that: The aluminum busbar substrate (3) is made of 1060 pure aluminum, and the cross-sectional area of ​​the aluminum busbar substrate (3) accounts for 70% to 80% of the cross-sectional area of ​​the aluminum busbar body (1).

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