Multifunctional composite coated copper busbar

Abstract

This utility model relates to the field of copper busbar technology and discloses a multifunctional composite coated copper busbar, including a base layer, an outer layer of which is wrapped with an intermediate protective layer, and an outer intelligent coating attached to the outer layer of the intermediate protective layer. The base layer includes a copper busbar body and a functional coating. The functional coating is attached to the outer layer of the copper busbar body. The intermediate protective layer includes a corrosion-resistant layer, an insulation layer, and an adhering particle layer. The inner layer of the insulation layer wraps around the outer layer of the corrosion-resistant layer, and the adhering particle layer is attached to the outer layer of the functional coating and the inner layer of the corrosion-resistant layer. Through the combination of the base layer, the intermediate protective layer, and the outer intelligent coating, the overall structural design enables the copper busbar to possess characteristics such as oxidation resistance, corrosion resistance, high insulation, wear resistance, efficient heat dissipation, and intelligent monitoring, significantly extending its service life, improving operational safety and reliability, reducing maintenance costs, and making it suitable for complex and variable electrical environments.

Description

Technical Field

[0001] This utility model relates to the field of copper busbar technology, specifically a multifunctional composite coated copper busbar. Background Technology

[0002] Traditional copper busbars are mostly made of bare copper or have only a simple protective coating. During long-term use, they are prone to oxidation reactions with oxygen and moisture in the air, forming an oxide film. This leads to increased contact resistance, which not only increases power loss but may also cause local overheating or even electrical failures. When copper busbars are used in special environments such as chemical plants or coastal areas, corrosive media such as acidic and alkaline gases and salt spray in the air will accelerate the corrosion of the copper, significantly shortening the service life of the copper busbar. Furthermore, the conductivity of the corroded copper busbar decreases, posing serious safety hazards.

[0003] Under complex operating conditions such as high humidity and high voltage, the insulation layer is prone to aging and damage, which can lead to accidents such as leakage and short circuits, threatening the safe operation of equipment and the safety of personnel. At the same time, during installation, maintenance and long-term use, the surface of copper busbars is easily subjected to mechanical damage such as friction and collision. The poor wear resistance of traditional copper busbars makes their surface prone to scratches and wear, which in turn affects their conductivity and structural strength. Utility Model Content

[0004] The purpose of this utility model is to solve the problems of poor oxidation resistance, easy increase in contact resistance, local overheating and electrical faults caused by oxidation, and insufficient corrosion resistance of traditional copper busbars. This utility model provides a multifunctional composite coated copper busbar.

[0005] To achieve the above objectives, this utility model specifically adopts the following technical solution:

[0006] A multifunctional composite coated copper busbar includes a base layer, an outer layer of which is wrapped with an intermediate protective layer, and an outer intelligent coating attached to the outer layer of the intermediate protective layer. The base layer includes a copper busbar body and a functional coating. The functional coating is attached to the outer layer of the copper busbar body. The intermediate protective layer includes a corrosion-resistant layer, an insulation layer, and an adhering particle layer. The inner layer of the insulation layer wraps around the outer layer of the corrosion-resistant layer. The adhering particle layer is attached to the outer layer of the functional coating and the inner layer of the corrosion-resistant layer. The outer intelligent coating includes a wear-resistant layer, a thermal management layer, and a thermosensitive color-changing layer. The thermal management layer is attached to the outer layer of the wear-resistant layer, and the thermosensitive color-changing layer is disposed on the outer surface of the thermal management layer.

[0007] Furthermore, the functional coating is an antioxidant coating composed of nano-sized titanium dioxide and aluminum oxide mixture, which has a large specific surface area and unique physicochemical properties, and can form a continuous and dense protective film on the surface of the copper busbar.

[0008] Furthermore, the corrosion-resistant layer is a hot-dip galvanized layer, a zinc-iron alloy layer and a pure zinc layer with good corrosion resistance, which effectively resists various corrosive environments such as the atmosphere and acids and alkalis. The insulation layer is made of cross-linked polyethylene material, which is melted and coated on the outside of the corrosion-resistant layer under high temperature and pressure through an extrusion molding process.

[0009] Furthermore, the adhering particle layer is made of micron-sized silica particles mixed with epoxy resin and is adhered to the surface of the functional coating and the corrosion-resistant layer by a spraying process, forming a rough adhering structure, which significantly increases the contact area and friction between the layers, thereby improving the adhesion and bonding stability between the intermediate protective layer and the bottom layer and the outer smart coating.

[0010] Furthermore, the wear-resistant layer is a tungsten carbide coating, which is prepared by chemical vapor deposition to form a tungsten carbide coating with high hardness and high wear resistance.

[0011] Furthermore, the thermal management layer is a high thermal conductivity ceramic coating, composed of aluminum nitride ceramic material, which is sprayed onto the outside of the wear-resistant layer after the aluminum nitride ceramic powder is heated to a molten state by plasma spraying or thermal spraying processes.

[0012] Furthermore, the thermochromic layer contains a thermochromic material that can respond sensitively to temperature changes and exhibit different colors in different temperature ranges.

[0013] Furthermore, the functional coating is firmly adhered to the copper busbar through a thermal spraying process.

[0014] Furthermore, the wear-resistant layer, the thermal management layer, and the thermosensitive color-changing layer are connected by a layer-by-layer coating process.

[0015] Compared with the prior art, this utility model provides a multifunctional composite coated copper busbar with the following advantages:

[0016] This multifunctional composite coated copper busbar combines an underlayer, an intermediate protective layer, and an outer intelligent coating. Its overall structural design gives the copper busbar characteristics such as oxidation resistance, corrosion resistance, high insulation, wear resistance, efficient heat dissipation, and intelligent monitoring, significantly extending its service life, improving operational safety and reliability, reducing maintenance costs, and making it suitable for complex and ever-changing electrical environments. Attached Figure Description

[0017] Figure 1 A three-dimensional view of the overall external structure of this utility model is provided.

[0018] Figure 2 A three-dimensional diagram showing the structural layers of the external intelligent coating of this utility model;

[0019] Figure 3A three-dimensional diagram showing the structure of the bottom and middle protective layers of this utility model;

[0020] Figure 4 This is a three-dimensional cross-sectional view showing the structure of the intermediate protective layer of this utility model.

[0021] In the diagram: 1. Bottom layer; 11. Copper busbar; 12. Functional coating; 2. Intermediate protective layer; 21. Corrosion resistant layer; 22. Insulation layer; 23. Adhesive particle layer; 3. Outer intelligent coating; 31. Wear resistant layer; 32. Thermal management layer; 33. Temperature-sensitive color-changing layer. Detailed Implementation

[0022] 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. Example 1:

[0023] like Figures 1-4 As shown, a multifunctional composite coated copper busbar includes a bottom layer 1, an outer layer of which is wrapped with an intermediate protective layer 2, and an outer intelligent coating 3 is attached to the outer layer of the intermediate protective layer 2.

[0024] like Figure 3 As shown, the bottom layer 1 includes a copper busbar body 11 and a functional coating 12. The copper busbar body 11 is made of high-purity electrolytic copper material and is formed by high-precision rolling or drawing process to ensure that it has excellent conductivity and stable physical structure, serving as the core carrier for current transmission. The functional coating 12 is attached to the outer layer of the copper busbar body 11 and forms a firm connection with the copper busbar body 11 through physical or chemical bonding.

[0025] Among them, the functional coating 12 is an anti-oxidation coating, which is composed of nano-sized titanium dioxide and aluminum oxide mixed materials. It has a large specific surface area and unique physical and chemical properties. It can form a continuous and dense protective film on the surface of the copper busbar 11, which can effectively isolate oxygen, water vapor and other substances from contact with the copper busbar 11, inhibit the oxidation reaction of copper, and improve the anti-oxidation ability and service life of the copper busbar.

[0026] The functional coating 12 is firmly attached to the copper busbar 11 through a thermal spraying process. The functional coating 12 and the surface of the copper busbar 11 form a mechanical interlock and metallurgical bond, thereby forming a firm and uniform functional coating 12.

[0027] like Figures 3-4As shown, the intermediate protective layer 2 includes a corrosion-resistant layer 21, an insulating layer 22, and an adhering particle layer 23. The inner layer of the insulating layer 22 wraps around the outer layer of the corrosion-resistant layer 21, and the adhering particle layer 23 is attached to the outer layer of the functional coating 12 and the inner layer of the corrosion-resistant layer 21.

[0028] Among them, the corrosion-resistant layer 21 is a hot-dip galvanized layer, which has a zinc-iron alloy layer and a pure zinc layer with good corrosion resistance, effectively resisting various corrosive environments such as the atmosphere and acids and alkalis;

[0029] Among them, the insulation layer 22 is made of cross-linked polyethylene material. Through the extrusion molding process, the cross-linked polyethylene material is melted under high temperature and high pressure and coated on the outside of the corrosion-resistant layer 21. After cooling, a continuous and uniform insulation layer is formed.

[0030] The attached particle layer 23 is made of micron-sized silica particles mixed with epoxy resin. It is attached to the surface of the functional coating 12 and the corrosion-resistant layer 21 by spraying process, forming a rough attachment structure, which significantly increases the contact area and friction between the layers, thereby improving the adhesion and bonding stability between the intermediate protective layer and the bottom layer 1 and the outer smart coating 3. Example 2:

[0031] like Figure 2 As shown, the outer smart coating 3 includes a wear-resistant layer 31, a thermal management layer 32, and a thermosensitive color-changing layer 33. The thermal management layer 32 is attached to the outer layer of the wear-resistant layer 31, and the thermosensitive color-changing layer 33 is disposed on the outer surface of the thermal management layer 32. The wear-resistant layer 31, the thermal management layer 32, and the thermosensitive color-changing layer 33 are connected by a layer-by-layer coating method.

[0032] Among them, the wear-resistant layer 31 is a tungsten carbide coating, which is prepared by chemical vapor deposition process to form a tungsten carbide coating with high hardness and high wear resistance.

[0033] Among them, the thermal management layer 32 is a high thermal conductivity ceramic coating, which is composed of aluminum nitride ceramic material. The aluminum nitride ceramic powder is heated to a molten state and then sprayed on the outside of the wear-resistant layer 31 through plasma spraying or thermal spraying process to form a continuous heat conduction channel to quickly dissipate the heat generated during the operation of the copper busbar.

[0034] Among them, the thermochromic layer 33 contains thermochromic material. The thermochromic material is mixed with additives such as transparent resin and uniformly coated on the outer surface of the thermal management layer 32 through a coating process. It can respond sensitively to temperature changes and present different colors in different temperature ranges, thereby realizing real-time and visual monitoring of the temperature of the copper busbar.

Claims

1. A multi-functional composite coated copper busbar comprising a base layer (1), characterized in that: The outer layer of the bottom layer (1) is wrapped with an intermediate protective layer (2), and the outer layer of the intermediate protective layer (2) is coated with an outer smart coating (3). The bottom layer (1) includes a copper busbar body (11) and a functional coating (12), the functional coating (12) being attached to the outer layer of the copper busbar body (11); The intermediate protective layer (2) includes a corrosion-resistant layer (21), an insulating layer (22), and an adhering particle layer (23). The inner layer of the insulating layer (22) is wrapped around the outer layer of the corrosion-resistant layer (21), and the adhering particle layer (23) is attached to the outer layer of the functional coating (12) and the inner layer of the corrosion-resistant layer (21). The outer smart coating (3) includes a wear-resistant layer (31), a thermal management layer (32) and a thermosensitive color-changing layer (33). The thermal management layer (32) is attached to the outer layer of the wear-resistant layer (31), and the thermosensitive color-changing layer (33) is disposed on the outer surface of the thermal management layer (32).

2. The multi-functional composite coated copper busbar according to claim 1, wherein: The functional coating (12) is an anti-oxidation coating that is firmly attached to the outer layer of the copper busbar (11) by a thermal spraying process, and can form a continuous and dense protective film on the surface of the copper busbar (11).

3. The multi-functional composite coated copper busbar according to claim 1, wherein: The corrosion-resistant layer (21) is a hot-dip galvanized layer, and the insulating layer (22) is made of cross-linked polyethylene material.

4. The multi-functional composite coated copper busbar of claim 1, wherein: The adhering particle layer (23) is attached to the surface of the functional coating (12) and the corrosion-resistant layer (21) by a spraying process, forming a rough adhering structure.

5. The multi-functional composite coated copper busbar of claim 1, wherein: The wear-resistant layer (31) is a tungsten carbide coating, prepared by chemical vapor deposition.

6. The multi-functional composite coated copper busbar of claim 1, wherein: The thermal management layer (32) is a high thermal conductivity ceramic coating made of aluminum nitride ceramic material.

7. The multi-functional composite coated copper busbar of claim 1, wherein: The thermochromic layer (33) contains a thermochromic material.

8. The multi-functional composite coated copper busbar of claim 1, wherein: The functional coating (12) is firmly attached to the copper busbar (11) through a thermal spraying process.

9. A multifunctional composite coated copper busbar according to claim 1, characterized in that: The wear-resistant layer (31), the thermal management layer (32), and the thermosensitive color-changing layer (33) are connected by a layer-by-layer coating process.

Images