A flexible conductive soft connection assembly of a new energy automobile with a multilayer composite structure

Abstract

The utility model discloses a new energy automobile with flexible conductive soft connection assembly of multilayer composite structure, including conductive layer, the upper and lower both sides of conductive layer all are provided with buffer layer, the outside of buffer layer is provided with insulating layer, the outside of insulating layer is provided with protective layer, and the both ends of conductive layer all are provided with connecting hole, the utility model discloses through setting conductive layer, buffer layer, insulating layer and protective layer, formed multilayer composite structure, improved the flexibility, conductive performance, corrosion resistance and antioxidant property of conductive soft connection assembly, can satisfy new energy automobile to the high performance requirement of conductive soft connection assembly, has wide application prospect.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle parts technology, specifically a multi-layer composite flexible conductive soft connection component for new energy vehicles. Background Technology

[0002] In the electrical systems of new energy vehicles, conductive flexible connectors play a crucial role, connecting key components such as batteries, motors, and electronic controls to transmit electrical energy. With the continuous development of new energy vehicle technology, the performance requirements for conductive flexible connectors are becoming increasingly stringent. Traditional conductive flexible connectors typically have a simple structure, generally made of a single conductive material, and have limitations in flexibility, conductivity, corrosion resistance, and oxidation resistance. During the operation of new energy vehicles, due to vehicle vibration, bumps, and temperature changes, traditional conductive flexible connectors are prone to breakage and poor contact, affecting the stable transmission of electrical energy and potentially causing safety accidents. Therefore, developing a flexible conductive flexible connector for new energy vehicles with a multi-layered composite structure that improves flexibility, conductivity, corrosion resistance, and oxidation resistance is of significant practical importance. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide a flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure, so as to solve the problems of insufficient flexibility, conductivity, corrosion resistance and oxidation resistance of traditional conductive soft connection components mentioned in the background art.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a multi-layer composite flexible conductive soft connection component for new energy vehicles, including a conductive layer, buffer layers on both the upper and lower sides of the conductive layer; an insulating layer on the outer side of the buffer layer; a protective layer on the outer side of the insulating layer; and connection holes at both ends of the conductive layer.

[0005] Furthermore, the conductive layer has an overall L-shaped structure, with the two connecting arms being rigid regions and the connection point between the two arms being a flexible region. This structural design gives the conductive layer a certain degree of rigidity in the connecting arm portion, facilitating connection with electrical components, while the connection point is flexible, enabling it to adapt to vibrations and deformations during vehicle operation and improving the reliability of the component.

[0006] Furthermore, the conductive layer includes a first conductive layer and a second conductive layer; both the first and second conductive layers are composed of multiple soft copper sheet layers arranged from top to bottom; the two ends of the multiple soft copper sheet layers are pressed together to form a rigid region, while the middle sections are independent, forming a flexible region. The soft copper sheet layers have good conductivity and flexibility. The rigid region formed by pressing the two ends together ensures the stability of the connection with the outside, while the independent structure in the middle enhances the flexibility of the conductive layer, enabling it to better adapt to complex working environments.

[0007] Furthermore, a spacer is provided between the rigid regions of the first conductive layer and / or the second conductive layer; the spacer is composed of multiple soft copper sheets laminated from top to bottom.

[0008] High-precision ultrasonic welding is used between adjacent soft copper sheets to ensure tight interlayer bonding and no incomplete soldering. The thickness of each soft copper sheet is controlled within the range of 0.1-0.3mm, and multiple sheets are stacked to form a composite structure with a gradient buffering effect.

[0009] The spacers enhance the overall strength and stability of the conductive layer, effectively dispersing stress concentration points and preventing metal fatigue in rigid areas due to repeated bending during high-frequency vibrations in vehicle operation. Simultaneously, the high ductility and interlayer sliding properties of the flexible copper sheets ensure excellent flexibility within a temperature range of -40℃ to 125℃, meeting the dynamic deformation requirements of new energy vehicles under complex operating conditions. Furthermore, the spacers optimize the heat dissipation path of the conductive layer; the gap structure formed by the multiple layers of flexible copper sheets aids air convection, reducing the temperature rise during module operation.

[0010] Furthermore, the buffer layer is an elastic rubber layer or a silicone layer, with a thickness of 0.5-2 mm. The elastic rubber layer, due to its high elasticity and resilience, can quickly deform and recover under conditions such as vehicle start-up, acceleration, and bumps, effectively buffering mechanical stress. The silicone layer possesses excellent high and low temperature resistance, maintaining its buffering effect even in extreme environments. Both materials have a dense microstructure, capable of converting vibration energy into heat energy for gradual dissipation. Simultaneously, they form a flexible isolation barrier between the conductive layer and external structural components, preventing wear and breakage risks caused by rigid contact, significantly improving the service life and reliability of the conductive flexible connection assembly.

[0011] Furthermore, the insulating layer is either a polyvinyl chloride (PVC) insulating layer or an epoxy resin insulating layer, with a thickness of 0.3-1.5 mm. PVC insulating layers, due to their excellent dielectric strength and chemical stability, maintain good insulation performance within an ambient temperature range of -15℃ to 60℃, effectively resisting acid and alkali corrosion and mechanical wear. Epoxy resin insulating layers, through their unique thermosetting molecular structure, form a dense protective barrier, capable of withstanding short-term high-temperature impacts up to 150℃, and possess excellent flame-retardant and self-extinguishing properties. Laboratory verification showed that neither insulating material exhibited current leakage under a 5000V voltage test. Combined with precisely controlled thickness parameters, this effectively blocks interlayer current crosstalk, significantly improving the electrical isolation performance and operational safety of high-voltage systems in new energy vehicles.

[0012] Furthermore, the protective layer is either a polytetrafluoroethylene (PTFE) protective layer or a nylon protective layer, with a thickness of 0.2-1 mm. This thickness range has been verified through multiple rounds of engineering, ensuring both protective performance and component flexibility. The PTFE protective layer possesses an extremely low coefficient of friction and excellent chemical stability, maintaining good physical properties across a wide temperature range of -196℃ to 260℃, effectively resisting acid and alkali corrosion and dust abrasion. The nylon protective layer is renowned for its high strength and toughness. Through optimized molecular chain structure, it maintains over 90% of its tensile strength even at 150℃ and possesses self-lubricating properties, significantly reducing wear rates under dynamic operating conditions. These two protective layers are tightly bonded to the buffer layer using a precision coating process, forming a three-dimensional protective system that effectively isolates external mechanical impacts, chemical corrosion, and thermal stress, providing comprehensive protection for the internal buffer layer, insulation layer, and conductive layer. Accelerated aging tests in the laboratory have verified that this extends the component's lifespan to more than 2.3 times that of traditional solutions.

[0013] The beneficial effects of this utility model are as follows: The multi-layer composite structure of this utility model includes a conductive layer, a buffer layer, an insulating layer, and a protective layer. The layers work together to give the conductive soft connection component good flexibility, buffer protection performance, insulation performance, and protective performance. It can effectively adapt to the complex working environment inside new energy vehicles and improve the reliability and service life of the component.

[0014] The conductive layer adopts a structure of a first conductive layer and a second conductive layer, both of which have flexible and rigid regions. The spacer ensures the stability of the conductivity, while the flexible region can meet the flexibility requirements of the component, and the rigid region facilitates connection, thus improving the practicality of the component.

[0015] The buffer layer, insulation layer, and protective layer are made of appropriate materials and thicknesses, giving full play to the functions of each layer. The buffer layer effectively protects the conductive layer, the insulation layer ensures electrical safety, and the protective layer improves the durability of the component. The overall structure is reasonably designed and has excellent performance. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

[0018] Figure 2 This is a schematic diagram of the conductive layer. Detailed Implementation

[0019] The technical solution of this utility model will be clearly and completely described below through specific embodiments.

[0020] refer to Figure 1 and Figure 2 This utility model discloses a multi-layer composite flexible conductive soft connection component for new energy vehicles, including a conductive layer 1, buffer layers 2 on both the upper and lower sides of the conductive layer 1, an insulating layer 3 on the outer side of the buffer layer 2, a protective layer 4 on the outer side of the insulating layer 3, and connection holes 5 at both ends of the conductive layer 1.

[0021] The conductive layer 1 has an overall L-shaped structure. The two connecting arms of the L-shaped structure are rigid regions, and the connection between the two connecting arms is a flexible region. The conductive layer 1 includes a first conductive layer 11 and a second conductive layer 12. Both the first conductive layer 11 and the second conductive layer 12 are composed of multiple soft copper sheet layers arranged from top to bottom. The two ends of the multiple soft copper sheet layers are pressed together to form a rigid region, and the middle parts are independent to form a flexible region. A spacer 13 is provided between the rigid regions of the first conductive layer 11 and / or the second conductive layer 12. The spacer 13 is composed of multiple soft copper sheet layers arranged from top to bottom and pressed together.

[0022] The buffer layer 2 is an elastic rubber layer or a silicone layer, and the thickness of the buffer layer 2 is 0.5-2 mm. The insulating layer 3 is a polyvinyl chloride insulating layer or an epoxy resin insulating layer, and the thickness of the insulating layer 3 is 0.3-1.5 mm. The protective layer 4 is a polytetrafluoroethylene protective layer or a nylon protective layer, and the thickness of the protective layer 4 is 0.2-1 mm.

[0023] In use, the conductive flexible connector assembly is connected to the electrical components of the new energy vehicle through the connection hole 5. The rigid area of ​​the conductive layer 1 is crimped to ensure the stability of the connection with the outside, while the flexible area can adapt to the vibration and deformation during vehicle operation, ensuring stable current transmission. The buffer layer 2 can absorb vibration and impact, protecting the conductive layer 1 from damage; the insulating layer 3 prevents current leakage and improves safety; the protective layer 4 protects the internal structure from the influence of the external environment and extends the service life of the component.

[0024] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. Those skilled in the art can make various modifications or equivalent substitutions to the present utility model within its substance and protection scope, and such modifications or equivalent substitutions should also be considered to fall within the protection scope of the present utility model's technical solution.

Claims

1. A flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure, characterized in that: The conductive layer (1) is characterized in that: a buffer layer (2) is provided on both the upper and lower sides of the conductive layer (1); an insulating layer (3) is provided on the outer side of the buffer layer (2); a protective layer (4) is provided on the outer side of the insulating layer (3); and a connection hole (5) is provided at both ends of the conductive layer (1).

2. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 1, characterized in that: The conductive layer (1) is an L-shaped structure. The two connecting arms of the L-shaped structure are rigid regions, and the connection between the two connecting arms is a flexible region.

3. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 1, characterized in that: The conductive layer (1) includes a first conductive layer (11) and a second conductive layer (12); the first conductive layer (11) and the second conductive layer (12) are both composed of multiple soft copper sheet layers arranged from top to bottom; the two ends of the multiple soft copper sheet layers are pressed together to form a rigid area, and the middle part is independent to form a flexible area.

4. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 3, characterized in that: A spacer (13) is provided between the rigid regions of the first conductive layer (11) and / or the second conductive layer (12); the spacer (13) is composed of multiple soft copper sheets laminated from top to bottom.

5. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 1, characterized in that: The buffer layer (2) is an elastic rubber layer or a silicone layer, and the thickness of the buffer layer (2) is 0.5-2mm.

6. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 1, characterized in that: The insulating layer (3) is a polyvinyl chloride insulating layer or an epoxy resin insulating layer, and the thickness of the insulating layer (3) is 0.3-1.5 mm.

7. The flexible conductive soft connection component for new energy vehicles with a multi-layer composite structure according to claim 1, characterized in that: The protective layer (4) is a polytetrafluoroethylene protective layer or a nylon protective layer, and the thickness of the protective layer (4) is 0.2-1mm.

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