A right piece soft copper bar structure for electrical connection

Abstract

The utility model discloses a right piece soft copper bar structure for electrical connection, including the soft copper bar body for connecting first electrical equipment terminal and second electrical equipment terminal, the soft copper bar body includes first fixed section, first connecting section, torsion section, second connecting section and second fixed section who sets in turn along the length direction of itself, first fixed section is used for with first electrical equipment terminal fixed connection, first connecting section is connected with first fixed section, torsion section is connected with second connecting section, second fixed section is used for with second electrical equipment terminal fixed connection. Can high -efficiently absorb non -coplanar non -parallel installation under equipment vibration, thermal expansion and contraction produce three -dimensional displacement, avoid terminal deformation or the falling of welding spot, prolong the life of transformer, inverter and other equipment, reduce maintenance cost. Still can reduce contact resistance, insulate corrosion, and the low conductivity attenuation rate reduces heat loss, guarantees the system stability.

Description

Technical Field

[0001] This utility model relates to the field of copper busbar technology, specifically to a right-side soft copper busbar structure for electrical connection. Background Technology

[0002] In the field of electrical connections, flexible copper busbars, as key components for conducting current and connecting equipment terminals, are widely used in new energy, industrial control, rail transportation, and other scenarios. In existing technologies, traditional copper busbars are mostly rigid straight bars or simply bent structures, making it difficult to adapt to the installation requirements where the first and second electrical equipment terminals are not coplanar or parallel.

[0003] When equipment vibrates or expands and contracts due to heat during operation, rigid copper busbars cannot compensate for relative displacement in three-dimensional space, which can easily lead to deformation of terminals, loosening of connections, and even short circuits and overheating. Although ordinary flexible copper busbars have a certain degree of flexibility, they lack a dedicated torsion compensation structure, have limited capacity to absorb three-dimensional displacement, and often suffer from stress concentration due to excessively small bending radii, thus reducing their service life. Utility Model Content

[0004] In order to overcome the shortcomings of existing technical solutions, this utility model provides a right-side soft copper busbar structure for electrical connection, which can effectively solve the problems mentioned in the background art.

[0005] The technical solution adopted by this utility model to solve its technical problem is:

[0006] A flexible copper busbar structure for electrical connection includes a flexible copper busbar body for connecting a first electrical equipment terminal and a second electrical equipment terminal. The flexible copper busbar body includes a first fixed section, a first connecting section, a torsion section, a second connecting section, and a second fixed section arranged sequentially along its own length direction. The first fixed section is used to fixally connect to the first electrical equipment terminal. The first connecting section is connected to the first fixed section. The torsion section is connected to the second connecting section. The second fixed section is used to fixally connect to the second electrical equipment terminal.

[0007] The twisting segment is a flat spiral structure with a predetermined twisting angle and length. The first end of the twisting segment is connected to the first connecting segment, and the second connecting segment is connected to the second end of the twisting segment.

[0008] The first fixed segment, the first connecting segment, the torsion segment, the second connecting segment, and the second fixed segment are located in different spatial planes. The torsion segment is configured to provide flexible displacement compensation force in three-dimensional space between the first fixed segment and the second fixed segment. The first fixed segment and the second fixed segment are in a non-coplanar and non-parallel relative position in the installation state. The helical axis of the torsion segment is perpendicular to the intersection line of the planes where the first fixed segment and the second fixed segment are located.

[0009] As a further description of the above technical solution, the twisted section is formed by winding multiple layers of flat copper strips, the cross-section of the twisted section is rectangular, and the layers of the twisted section are isolated by an insulating film.

[0010] As a further description of the above technical solution, the first connecting segment and the second connecting segment are arc-shaped curved structures with a predetermined radius of curvature, and the radius of curvature is not less than 5 times the thickness of the soft copper busbar body.

[0011] As a further description of the above technical solution, at least one mounting hole for bolt connection is provided on the first fixing section and the second fixing section, and the shape of the mounting hole is one of a circular hole, an oblong hole or an irregular hole.

[0012] As a further description of the above technical solution, the torsion angle of the torsion segment ranges from 45° to 180°.

[0013] As a further description of the above technical solution, the surface of the soft copper busbar structure is provided with a composite plating layer, which consists of a nickel underlayer, a silver intermediate layer and an anti-oxidation tin outer layer from the inside to the outside.

[0014] As a further description of the above technical solution, the total length of the soft copper busbar body is 100mm-1000mm, the thickness of the soft copper busbar body is 0.5mm to 3.0mm, and the width of the soft copper busbar body is 10mm to 80mm.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] The right-side flexible copper busbar structure for electrical connection of this utility model has at least one of the following beneficial effects during use:

[0017] Firstly, the flat, spiral-shaped torsion section (45°-180° torsion angle, axis perpendicular to the plane intersection of the fixed section) and the arc-shaped connecting section (radius of curvature ≥ 5 times the thickness) work together to efficiently absorb the three-dimensional displacement caused by equipment vibration and thermal expansion and contraction under non-coplanar and non-parallel installation, preventing terminal deformation or solder joint detachment, extending the life of transformers, inverters, and other equipment, and reducing maintenance costs. Secondly, the multi-layer flat copper strip design of the torsion section enhances current carrying capacity, while the composite plating (nickel base + silver middle + tin outer) reduces contact resistance, isolates corrosion, has a low conductivity attenuation rate, reduces heat loss, and ensures system stability. Thirdly, the multi-shaped mounting hole is compatible with various deviations, and sizes ranging from 100-1000mm cover multiple scenarios, improving assembly efficiency; the interlayer insulating film prevents short circuits, and the arc-shaped structure prevents stress concentration, ensuring structural reliability and adaptability to multiple fields such as new energy and industrial control. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the overall structure of a right-side flexible copper busbar structure for electrical connection according to the present invention;

[0019] Figure 2 This is a side view of a right-side flexible copper busbar structure for electrical connection according to the present invention.

[0020] Figure 3 This is a partial structural diagram of a right-side flexible copper busbar structure for electrical connection according to the present invention.

[0021] Numbering on the map:

[0022] 1. First fixed section; 2. First connecting section; 3. Torsion section; 4. Second connecting section; 5. Second fixed section; 6. Insulating film; 7. Mounting hole; 8. Composite coating. Detailed Implementation

[0023] 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.

[0024] like Figure 1-3 As shown, this utility model provides a right-side flexible copper busbar structure for electrical connection, including a flexible copper busbar body for connecting a first electrical equipment terminal and a second electrical equipment terminal. The flexible copper busbar body includes a first fixed section 1, a first connecting section 2, a torsion section 3, a second connecting section 4, and a second fixed section 5 arranged sequentially along its own length direction. The first fixed section 1 is used to fix and connect to the first electrical equipment terminal. The first connecting section 2 is connected to the first fixed section 1. The torsion section 3 is connected to the second connecting section 4. The second fixed section 5 is used to fix and connect to the second electrical equipment terminal.

[0025] Current enters from the first electrical equipment terminal into the first fixed section 1, is guided through the arc-shaped first connecting section 2 to the flat spiral twisting section 3, and then through the second connecting section 4 to the second fixed section 5, and finally enters the second electrical equipment terminal to realize the electrical connection between the two devices.

[0026] The five segments are located in different spatial planes. The first and second fixed segments 5 are "rigid connection ends" (fixed to the equipment terminals), the first and second connecting segments 4 are "flexible transition ends" (arc bending buffer), and the torsion segment 3 is "core compensation end" (three-dimensional displacement absorption). The three work together to achieve a functional closed loop of "fixed-transition-compensation-transition-fixed".

[0027] The twisting segment 3 is a flat spiral structure with a predetermined twisting angle and length. The first end of the twisting segment 3 is connected to the first connecting segment 2, and the second connecting segment 4 is connected to the second end of the twisting segment 3.

[0028] The torsion segment 3 is a "flat spiral structure with a predetermined torsion angle (45°-180°) and length", and its spiral axis is perpendicular to the intersection of the planes where the first and second fixed segments 5 are located. This design allows the torsion segment 3 to undergo elastic deformation in multiple directions in three-dimensional space (such as torsion around the spiral axis, expansion and contraction along the axis, and bending perpendicular to the axis), and can directly absorb the radial and axial displacements of the two fixed segments in a non-coplanar state. At the same time, the flat spiral structure has a uniform stress distribution during deformation, avoiding local overload fracture.

[0029] The first fixed segment 1, the first connecting segment 2, the torsion segment 3, the second connecting segment 4, and the second fixed segment 5 are located in different spatial planes. The torsion segment 3 is configured to provide flexible displacement compensation force in three-dimensional space between the first fixed segment 1 and the second fixed segment 5. The first fixed segment 1 and the second fixed segment 5 are in a non-coplanar and non-parallel relative position in the installation state. The spiral axis of the torsion segment 3 is perpendicular to the intersection line of the planes where the first fixed segment 1 and the second fixed segment 5 are located.

[0030] The twisted section 3 is "made of multiple layers of flat copper strips, with the layers separated by an insulating film 6" - the multi-layer design can increase the conductive cross-sectional area (enhancing current carrying capacity and adapting to high current conditions), while the insulating film 6 prevents short circuits between layers and ensures that the current is conducted along a predetermined path. At the same time, the multi-layer structure makes the deformation of the twisted section 3 more uniform and improves the stability of flexible compensation.

[0031] Furthermore, the torsion section 3 is formed by winding multiple layers of flat copper strips. The cross-section of the torsion section 3 is rectangular, and the layers of the torsion section 3 are isolated by an insulating film 6. The torsion section 3 can adapt to non-coplanar and non-parallel installation scenarios, effectively absorbing three-dimensional displacements (radial, axial, and angular) caused by equipment vibration and thermal expansion and contraction. This prevents deformation and solder joint detachment of equipment terminals due to long-term stress, extends the service life of electrical equipment (such as transformers and inverters), and reduces fault repair costs.

[0032] It boasts strong current-carrying capacity (suitable for high-current applications from 100A to 1000A), low resistance (reducing Joule heat loss during current transmission and preventing localized overheating), and no oxidation or corrosion issues during long-term use. Its conductivity degradation rate is ≤5% (compared to 15%-20% for industry-standard copper busbars), ensuring stable operation of the electrical system. The interlayer insulation film 6 prevents short-circuit faults, and the composite coating 8 resists humid, acidic, and alkaline environments.

[0033] Furthermore, the first connecting segment 2 and the second connecting segment 4 are arc-shaped bending structures with a predetermined radius of curvature, which is not less than 5 times the thickness of the soft copper busbar body. The arc-shaped structure of the first and second connecting segments 4 avoids stress concentration caused by right-angle bending (preventing long-term breakage) and provides additional flexible buffering. Together with the torsion segment 3, it achieves "compensation-buffering" linkage, further reducing the stress load on the equipment terminals.

[0034] Furthermore, the first fixing section 1 and the second fixing section 5 are provided with at least one mounting hole 7 for bolt connection, and the shape of the mounting hole 7 is one of a circular hole, an oblong hole, or an irregular hole.

[0035] The first and second fixing sections 5 are equipped with "circular holes, oblong holes, or irregularly shaped holes"—circular holes are suitable for precise installation scenarios, oblong holes can accommodate minor deviations in the installation position (eliminating the need to re-process terminals and reducing assembly accuracy requirements), and irregularly shaped holes are suitable for special terminal structures, improving engineering assembly efficiency.

[0036] Furthermore, the torsion angle of the torsion segment 3 ranges from 45° to 180°.

[0037] The surface of the soft copper busbar structure is provided with a composite plating layer 8, which consists of a nickel bottom layer, a silver intermediate layer, and an anti-oxidation tin outer layer from the inside out.

[0038] The soft copper busbar has a composite plating layer consisting of a nickel base layer, a silver intermediate layer, and an anti-oxidation tin outer layer. The nickel base layer enhances the adhesion between the plating layer and the copper busbar (preventing the plating layer from peeling off), the silver intermediate layer reduces contact resistance (improving conductivity and reducing Joule heat loss), and the tin outer layer isolates the copper busbar from air and moisture (preventing oxidation and corrosion of the copper busbar and ensuring long-term stable conductivity).

[0039] Furthermore, the total length of the soft copper busbar body is 100mm-1000mm, the thickness of the soft copper busbar body is 0.5mm to 3.0mm, and the width of the soft copper busbar body is 10mm to 80mm.

[0040] The flexible copper busbar has a length of 100mm-1000mm, a thickness of 0.5mm-3.0mm, and a width of 10mm-80mm. Different lengths can accommodate different equipment spacings, and the thickness / width combination can adjust the current carrying capacity (the greater the width / thickness, the stronger the current carrying capacity), which can cover the current and space requirements of various scenarios such as low-voltage electrical appliances, new energy storage, and industrial control cabinets.

[0041] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A flexible copper busbar structure for electrical connection, comprising a flexible copper busbar body for connecting a first electrical equipment terminal and a second electrical equipment terminal, characterized in that, The flexible copper busbar body includes a first fixed section, a first connecting section, a torsion section, a second connecting section, and a second fixed section arranged sequentially along its own length direction. The first fixed section is used to be fixedly connected to a first electrical equipment terminal. The first connecting section is connected to the first fixed section. The torsion section is connected to the second connecting section. The second fixed section is used to be fixedly connected to a second electrical equipment terminal. The twisting segment is a flat spiral structure with a predetermined twisting angle and length. The first end of the twisting segment is connected to the first connecting segment, and the second connecting segment is connected to the second end of the twisting segment. The first fixed segment, the first connecting segment, the torsion segment, the second connecting segment, and the second fixed segment are located in different spatial planes. The torsion segment is configured to provide flexible displacement compensation force in three-dimensional space between the first fixed segment and the second fixed segment. The first fixed segment and the second fixed segment are in a non-coplanar and non-parallel relative position in the installation state. The helical axis of the torsion segment is perpendicular to the intersection line of the planes where the first fixed segment and the second fixed segment are located.

2. The right-side flexible copper busbar structure for electrical connection according to claim 1, characterized in that: The twisted section is formed by winding multiple layers of flat copper strips. The cross-section of the twisted section is rectangular, and the layers of the twisted section are separated by an insulating film.

3. The right-side flexible copper busbar structure for electrical connection according to claim 1, characterized in that: The first connecting segment and the second connecting segment are arc-shaped curved structures with a predetermined radius of curvature, the radius of curvature being no less than 5 times the thickness of the soft copper busbar body.

4. The right-side flexible copper busbar structure for electrical connection according to claim 1, characterized in that: The first fixing section and the second fixing section are provided with at least one mounting hole for bolt connection, and the mounting hole is one of the following shapes: circular hole, oblong hole, or irregular hole.

5. A right-side flexible copper busbar structure for electrical connection according to claim 1 or 2, characterized in that: The torsion angle of the torsion segment ranges from 45° to 180°.

6. The right-side flexible copper busbar structure for electrical connection according to claim 1, characterized in that: The surface of the soft copper busbar structure is provided with a composite plating layer, which consists of a nickel underlayer, a silver intermediate layer, and an anti-oxidation tin outer layer from the inside out.

7. The right-side flexible copper busbar structure for electrical connection according to claim 1, characterized in that: The total length of the soft copper busbar body is 100mm-1000mm, the thickness of the soft copper busbar body is 0.5mm to 3.0mm, and the width of the soft copper busbar body is 10mm to 80mm.

Images