A positive electrode copper braid structure having an anti-wear property

Abstract

The utility model discloses a positive pole copper braiding structure with anti-abrasion characteristic, including the flat strip shape of the band body that is formed by the braiding of multiple tinned copper wires and the connecting end part of setting in the both ends of band body, at least one main working surface of band body is equipped with insulating protective layer, insulating protective layer is made of the flexible insulating material of low friction coefficient of bending resistance, and through hot pressing compound or injection molding is covered in the copper wire surface of band body, the connecting end part is equipped with the thickening portion that has passed through the thickening processing of calendering, give consideration to flexible and conductive efficiency, and tinned layer forms the compact oxidation film through electrochemical passivation, can insulate corrosive medium, avoid resistance to rise, can prevent abrasion, bending resistance, can insulate positive and negative pole, and eliminate short circuit risk. The connecting end part calendering thickening cooperation thickness gradual change area, improve the tensile strength greatly, eliminate stress concentration, prevent the connection tear.

Description

Technical Field

[0001] This utility model relates to the field of positive electrode copper braiding technology, specifically a positive electrode copper braiding structure with wear-resistant properties. Background Technology

[0002] In high-current transmission scenarios such as new energy vehicle battery packs, energy storage systems, and high-power inverters, the positive electrode copper braided structure is a core component for achieving low-resistance current conduction and flexible assembly. Existing positive electrode copper braided structures mostly use ordinary copper wire braiding, which has several technical defects: First, some structures use single-strand thick-diameter copper wire or low braiding density (below 80%), making it difficult to balance flexibility and conductivity stability. This results in either excessive rigidity leading to breakage or loose copper wire contact causing current concentration, easily generating Joule heating overload under high current. Second, the copper wire surface is often simply tin-plated without a dedicated protective structure, making it susceptible to friction and wear during use. Furthermore, the tin plating layer is prone to oxidation and corrosion, leading to increased resistance and even short-circuit risks. Third, the connection ends often lack thickening treatment or have abrupt thickness changes, making them prone to cracking due to stress concentration during assembly, and resulting in high connection contact resistance (over 5mΩ), affecting conduction efficiency. Utility Model Content

[0003] In order to overcome the shortcomings of existing technical solutions, this utility model provides a positive electrode copper braided structure with wear-resistant properties, which can effectively solve the problems mentioned in the background art.

[0004] The technical solution adopted by this utility model to solve its technical problem is:

[0005] A positive electrode copper braided structure with wear-resistant properties includes a flat strip body woven from multiple strands of tin-plated copper wires and connecting ends disposed at both ends of the strip body. An insulating protective layer is provided on at least one main working surface of the strip body. The insulating protective layer is made of a flexible insulating material that is resistant to bending and has a low coefficient of friction, and is coated onto the surface of the copper wires of the strip body by hot pressing or injection molding.

[0006] The connecting end is provided with a thickened part that has undergone rolling and thickening treatment. The thickness of the thickened part is greater than the thickness of the main body of the belt. A gentle thickness gradient zone is formed between the thickened part and the main body of the belt. A connecting hole is provided on the thickened part.

[0007] As a further description of the above technical solution, the material of the insulating protective layer is a modified polyimide film, a polytetrafluoroethylene impregnation layer, or a silicone rubber composite material, and the thickness of the insulating protective layer is 0.05mm-0.2mm.

[0008] As a further description of the above technical solution, all edges of the tape and the insulating protective layer are provided with smooth transition surfaces, and the radius of curvature R of the smooth transition surfaces is 0.3mm-0.5mm.

[0009] As a further description of the above technical solution, the thickening process of the thickened part makes its thickness 1.5 to 3 times the thickness of the main body of the strip, and the cross section of the thickened part has a U-shaped groove structure, with its two sides turned up to wrap around and press the edge of the end of the strip.

[0010] As a further description of the above technical solution, the copper wire braiding density of the strip is 80%-95%, and the diameter of the tin-plated copper wire is 0.05mm-0.1mm.

[0011] As a further description of the above technical solution, the surface of the tin-plated copper wire undergoes electrochemical passivation treatment to form a dense oxide protective film.

[0012] Compared with the prior art, the beneficial effects of this utility model are:

[0013] The positive electrode copper braided structure of this utility model with wear-resistant properties has at least one of the following beneficial effects during use:

[0014] The tape body is woven with 0.05-0.1mm tin-plated copper wire at a density of 80%-95%, balancing flexibility and conductivity. The tin plating layer undergoes electrochemical passivation to form a dense oxide film, which isolates corrosive media and prevents resistance increases. At least one main surface is equipped with an insulating protective layer made of modified polyimide or other materials, which is hot-pressed or injection-molded to prevent wear and bending, and to isolate the positive and negative poles, eliminating the risk of short circuits. The connection ends are rolled and thickened to 1.5-3 times the thickness of the tape body, with U-shaped grooves for fixing the copper wires. Combined with a thickness gradient zone, this significantly improves tensile strength, eliminates stress concentration, and prevents connection tearing. Various connection methods, such as laser welding, are available to meet different assembly requirements. The smooth edge transition also prevents scratching adjacent components and dust accumulation and corrosion, effectively extending the overall service life and ensuring stable current transmission and safe use. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of a positive electrode copper braided structure with wear-resistant properties according to this utility model.

[0016] Figure 2 This is a top view schematic diagram of a positive electrode copper braided structure with wear-resistant properties according to this utility model;

[0017] Figure 3 This is a partial perspective view of a positive electrode copper braided structure with wear-resistant properties according to this utility model.

[0018] Numbering on the map:

[0019] 1. Belt body; 2. Connecting end; 3. Tinned copper wire; 4. Insulating protective layer; 5. Smooth transition surface; 6. Thickened part; 7. Connecting hole; 8. Oxidation protective film. Detailed Implementation

[0020] 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.

[0021] like Figure 1-3 As shown, this utility model provides a positive electrode copper braided structure with wear-resistant properties, including a flat strip-shaped strip body 1 woven from multiple strands of tin-plated copper wires 3 and connecting ends 2 disposed at both ends of the strip body 1. The characteristic is that an insulating protective layer 4 is provided on at least one main working surface of the strip body 1. The insulating protective layer 4 is made of a flexible insulating material that is resistant to bending and has a low coefficient of friction, and is coated onto the surface of the copper wires of the strip body 1 by hot pressing or injection molding.

[0022] Copper wires provide a low-resistance path for current transmission. The "multi-strand braiding" rather than a single copper wire increases the flexibility of the strip by distributing the stress on the wires (avoiding the fragility of rigid structures). Simultaneously, the parallel arrangement of multiple strands increases the conductive cross-sectional area, making it suitable for high-current applications (e.g., 100A-500A). The tin plating layer isolates the copper from air, initially inhibiting copper oxidation (which increases resistance by more than 30%), and reducing the contact resistance between the copper wires, thus minimizing Joule heat loss during current transmission.

[0023] The connecting end 2 is provided with a thickened part 6 that has undergone rolling and thickening treatment. The thickness of the thickened part 6 is greater than the thickness of the main body of the belt 1. A gentle thickness gradient zone is formed between the thickened part 6 and the main body of the belt 1. The thickened part 6 is provided with a connecting hole 7.

[0024] The flat structure reduces the space occupied in the thickness direction, making it suitable for compact installation environments (such as battery packs and inverter interiors); the high-density braiding of 80%-95% ensures tight contact between copper wires, avoiding "current concentration" (overload and melting of a single copper wire), while maintaining a certain degree of flexibility (too low a braiding density will lead to decreased conductivity, while too high a density will result in a loss of flexibility). The diameter of the copper wires is 0.05mm-0.1mm, further enhancing the bending ability of the braided structure (the minimum bending radius can reach 5-10mm), avoiding the stiffness of the belt caused by thicker copper wires.

[0025] Furthermore, the material of the insulating protective layer 4 is a modified polyimide film, a polytetrafluoroethylene impregnation layer, or a silicone rubber composite material, and the thickness of the insulating protective layer 4 is 0.05mm-0.2mm.

[0026] The insulating protective layer 4 concentrates the friction on the surface of the protective layer, rather than directly abrading the copper wire. It also ensures that the protective layer will not crack or fall off when the tape 1 is repeatedly bent during assembly or use, isolating the positive electrode tape 1 from the negative electrode / grounding components and avoiding the risk of short circuit. The rounded edge design further reduces the risk of scratches, extending the product's lifespan and resistance to vibration.

[0027] Furthermore, all edges of the belt body 1 and the insulating protective layer 4 are provided with smooth transition surfaces 5, and the radius of curvature R of the smooth transition surfaces 5 is 0.3mm-0.5mm.

[0028] The smooth transition surface 5 at the edge is formed through precision grinding, laser edge melting, or chemical etching. The hot-pressing composite process uses high temperature and pressure to eliminate interlayer gaps, preventing moisture and dust from entering and causing copper wire corrosion. The injection molding coating process fills the gaps between the copper wires, forming a continuous, unbroken protective film to avoid localized copper wire exposure. The thickness of the insulating protective layer 4 ensures wear resistance while avoiding excessive thickness that could reduce the flexibility of the strip 1.

[0029] Furthermore, the thickening process of the thickened portion 6 makes its thickness 1.5 to 3 times that of the main body of the strip 1, and the cross-section of the thickened portion 6 is a U-shaped groove structure, with its two sides turned up to wrap around and press the edge of the end of the strip 1.

[0030] The thickened part 6 increases the material volume of the connection part, which on the one hand improves the mechanical strength (tensile strength is increased to 1.8-2.5 times that of the main body of the strip 1), withstands welding thermal stress or bolt tightening force, and avoids tearing at the connection point; on the other hand, it increases the conductive cross-sectional area, reduces the current density, reduces Joule heat generation, and avoids overheating damage.

[0031] The thickness transitions smoothly from the belt 1 to the thickened section 6, which can eliminate stress concentration caused by "thickness abrupt change" (the stress concentration factor decreases from 3-5 during the abrupt change to 1.2-1.5 during the gradual change), and prevent fatigue cracks from forming in the belt 1 under bending or vibration conditions.

[0032] The two sides of the U-shaped groove are turned up to tightly press the braided copper wire at the end of the strip body 1. Fixing the position of the copper wire can prevent the braided structure from becoming loose (preventing a single copper wire from detaching and reducing the conductive cross-sectional area) and form a "mechanical interlock". This enhances the bonding strength between the thickened part 6 and the strip body 1 and prevents the two from separating during connection.

[0033] Furthermore, the copper wire weaving density of the strip body 1 is 80%-95%, and the diameter of the tin-plated copper wire 3 is 0.05mm-0.1mm.

[0034] Removing sharp edges through precision grinding, laser edge melting, or chemical etching can eliminate "stress singularities," preventing the protective layer at the edge from cracking due to stress concentration; prevent scratching adjacent insulating components during assembly; and reduce dust and impurity accumulation at the edges, thus lowering the risk of corrosion.

[0035] Furthermore, the thickened portion 6 is connected to the external electrode by laser welding, ultrasonic welding, or bolt fixing through the connection hole 7.

[0036] A "gapless connection" is achieved through metallurgical bonding (laser) or plastic deformation (ultrasonic), with a contact resistance of <5mΩ, ensuring stable current transmission and eliminating the need for high temperatures (ultrasonic), thus avoiding damage to the protective layer. Bolt fixing is adaptable to detachable scenarios (such as later maintenance), and the thickened part 6 can withstand the bolt tightening torque, preventing the belt body 1 from being crushed.

[0037] Furthermore, the surface of the tin-plated copper wire 3 undergoes electrochemical passivation treatment to form a dense oxide protective film 8.

[0038] By applying a specific current / voltage, a uniform (10-50 nm) and dense oxide protective film 8 (mainly composed of SnO2) is formed on the surface of the tin plating layer. This film has high chemical stability and can isolate the tin layer from oxygen, moisture, and corrosive media (such as electrolytes), preventing oxidation or corrosion of the tin layer, while not affecting its conductivity.

[0039] 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 positive electrode copper braid structure having a wear prevention property, comprising a flat band-shaped band body formed by braiding a plurality of tinned copper wires, and a connection end portion provided at both ends of the band body, characterized in that, An insulating protective layer is provided on at least one main working surface of the tape. The insulating protective layer is made of a flexible insulating material that is resistant to bending and has a low coefficient of friction, and is coated onto the surface of the copper wire of the tape by hot pressing or injection molding. The connecting end is provided with a thickened part that has undergone rolling and thickening treatment. The thickness of the thickened part is greater than the thickness of the main body of the belt. A gentle thickness gradient zone is formed between the thickened part and the main body of the belt. A connecting hole is provided on the thickened part.

2. The positive electrode copper braided structure with wear-resistant properties according to claim 1, characterized in that: The insulating protective layer is made of modified polyimide film, polytetrafluoroethylene impregnation layer or silicone rubber composite material, and the thickness of the insulating protective layer is 0.05mm-0.2mm.

3. The positive electrode copper braided structure with wear-resistant properties according to claim 1, characterized in that: All edges of the tape and the insulating protective layer are provided with smooth transition surfaces, and the radius of curvature R of the smooth transition surfaces is 0.3mm-0.5mm.

4. The positive electrode copper braided structure with wear-resistant properties according to claim 1, characterized in that: The thickened portion is calendered and thickened to make its thickness 1.5 to 3 times that of the main body of the strip, and the cross-section of the thickened portion is a U-shaped groove structure, with its two sides turned up to wrap around and press the edge of the end of the strip.

5. The positive electrode copper braided structure with wear-resistant properties according to claim 1, characterized in that: The copper wire weaving density of the strip is 80%-95%, and the diameter of the tin-plated copper wire is 0.05mm-0.1mm.

6. The positive electrode copper braided structure with wear-resistant properties according to claim 1, characterized in that: The surface of the tin-plated copper wire undergoes electrochemical passivation treatment to form a dense oxide protective film.

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