New energy vehicle laminated insulation soft busbar
By using multi-layer socket components on the laminated insulated flexible busbars of new energy vehicles and using specific materials and adhesives to fix the copper conductors, the problem of easy separation of the insulation layer is solved, and the high strength and durability of the busbars are achieved.
Patent Information
- Application Number
- CN202520805721.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-25
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-04-25
AI Technical Summary
The insulation layer of existing laminated insulated flexible busbars for new energy vehicles is prone to separation from the busbar during use, resulting in insufficient protection, especially when bent or misaligned.
The busbar body is protected by a multi-layer socket assembly, including an outer insulating protective sleeve, an isolation sleeve, a braided sleeve, a bend-resistant protective sleeve, and a buffer layer. Insulating rubber, aramid fiber or polyester fiber, TPE thermoplastic elastomer or TPU thermoplastic polyurethane and other materials are used to enhance tensile strength and bend resistance, and thin copper sheet conductors are fixed with glue.
It effectively prevents the busbar from cracking and separating during bending, improves overall strength and service life, and enhances insulation performance.
Smart Images
Figure CN224682818U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electrical equipment technology, specifically a laminated insulated flexible busbar for new energy vehicles. Background Technology
[0002] New energy vehicle laminated insulated flexible busbars, also known as laminated insulated flexible busbars or flexible busbars, are made of multiple layers of flat, thin copper conductors that are corona-resistant, with an outer insulating layer extruded. These busbars have a multi-layered composite structure and typically use PET as the insulation material, offering high cost-effectiveness. In new energy vehicles, laminated insulated flexible busbars are mainly used for high-voltage connections, running through the power battery, electric drive system, and other electronic components. They are an indispensable component of the vehicle's electrical architecture. Compared to traditional cables and busbars, laminated insulated flexible busbars have significant advantages in both electrical and mechanical performance.
[0003] Regarding the aforementioned technologies, insulated flexible busbars are made by stacking multiple layers of flat thin copper conductors and then covering the stacked layers with an insulation layer through extrusion. However, a single insulation material is insufficient to protect the busbar, especially when the busbar is bent or misaligned during use to achieve the purpose of connection, which may very likely cause the insulation layer to separate from the busbar.
[0004] Therefore, this utility model provides a laminated insulated flexible busbar for new energy vehicles to solve the above problems. Utility Model Content
[0005] To address the shortcomings of existing technologies, this utility model provides a laminated insulated flexible busbar for new energy vehicles, which solves the aforementioned problems.
[0006] To achieve the above objectives, this utility model is implemented through the following technical solution: a new energy vehicle laminated insulated soft busbar, including a busbar body, a multi-layer socket assembly installed on the outer wall of the busbar body, the busbar body being made of multiple anti-corona flat thin copper sheet conductors stacked together, and two connection holes being opened on the left and right sides of the outer wall of the busbar body.
[0007] The multi-layer socket assembly includes an outer insulating protective sleeve, an isolation sleeve installed on the outer wall of the busbar body, a braided sleeve installed on the outer wall of the isolation sleeve, a bend-resistant protective sleeve installed on the outer wall of the braided sleeve, a buffer layer installed on the outer wall of the bend-resistant protective sleeve, the buffer layer being fixedly connected to the inner wall of the outer insulating protective sleeve, and isolation strips being fixedly installed on both sides of the outer insulating protective sleeve and on the outer wall of the busbar body.
[0008] The above technical solution can provide good protection for the busbar body and prevent cracking and separation during subsequent bending.
[0009] Furthermore, the isolation sleeve is made of insulating rubber and is fitted onto the outer wall of the busbar body. Multiple thin copper conductors on the busbar body are connected and fixed to each other by adhesive.
[0010] Through the above technical solution, the busbar body is composed of stacked thin copper conductors.
[0011] Furthermore, the braided sleeve is made of aramid fiber or polyester fiber as the main raw material. The braided sleeve material is lightweight and high-strength, which is used to increase tensile strength and protect the busbar body from bending damage.
[0012] Through the above technical solution, the braided sleeve can increase the overall strength of the busbar body and prevent damage caused by bending.
[0013] Furthermore, the flexural protective sleeve uses TPE thermoplastic elastomer or TPU thermoplastic polyurethane as the main raw material, which has good flexural resistance, abrasion resistance and tear resistance.
[0014] Through the above technical solutions, the bend-resistant protective sleeve has good bend resistance, abrasion resistance, and tear resistance.
[0015] Furthermore, the internal structure of the buffer layer is a honeycomb support.
[0016] Through the above technical solution, when the whole is subjected to external pressure, the buffer layer can effectively buffer and support the pressure.
[0017] Furthermore, the isolation strip is mainly used to isolate the sidewalls of the outer insulating protective sleeve.
[0018] Through the above technical solutions, the isolation strip can encapsulate the buffer layer, the bend-resistant protective sleeve, the woven sleeve, and the isolation sleeve. Beneficial effects
[0019] This utility model provides a laminated insulated flexible busbar for new energy vehicles. Compared with the prior art, it has the following advantages:
[0020] (1) The new energy vehicle laminated insulated soft busbar, through the isolation strip, is mainly used to isolate the side wall of the outer insulating protective sleeve. It has a sealing function for the buffer layer, the bending-resistant protective sleeve, the braided sleeve and the isolation sleeve. The isolation sleeve is made of insulating rubber and is sleeved on the outer wall of the busbar body. The braided sleeve is made of aramid fiber or polyester fiber as the main raw material. The material is light and has high strength to increase the tensile strength and protect the busbar body from bending damage. The bending-resistant protective sleeve is made of TPE thermoplastic elastomer or TPU thermoplastic polyurethane as the main raw material. It has good bending resistance, friction resistance and tear resistance. The internal structure of the buffer layer is a honeycomb support, which can provide good support after being subjected to external pressure. Attached Figure Description
[0021] Figure 1 This is a front view of the overall structure of this utility model;
[0022] Figure 2 This is a partial sectional view of the present invention;
[0023] Figure 3 This is a utility model Figure 2 Enlarged view of the structure at point A.
[0024] In the figure: 1. Busbar body; 2. Connecting hole; 3. Multi-layer socket assembly; 31. Outer insulating protective sleeve; 32. Isolation strip; 33. Buffer layer; 34. Bending-resistant protective sleeve; 35. Braided sleeve; 36. Isolation sleeve. Detailed Implementation
[0025] 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.
[0026] Example 1:
[0027] Please see Figures 1-3 A new energy vehicle laminated insulated flexible busbar includes a busbar body 1, a multi-layer socket assembly 3 installed on the outer wall of the busbar body 1, the busbar body 1 is made of multiple anti-corona flat thin copper sheet conductors stacked together, and two connection holes 2 are opened on the left and right sides of the outer wall of the busbar body 1.
[0028] The multi-layer socket assembly 3 includes an outer insulating protective sleeve 31, an isolation sleeve 36 installed on the outer wall of the busbar body 1, a braided sleeve 35 sleeved on the outer wall of the isolation sleeve 36, a bend-resistant protective sleeve 34 installed on the outer wall of the braided sleeve 35, a buffer layer 33 installed on the outer wall of the bend-resistant protective sleeve 34, and a buffer layer 33 fixedly connected to the inner wall of the outer insulating protective sleeve 31. Isolation strips 32 are fixedly installed on both sides of the outer insulating protective sleeve 31 and sleeved on the outer wall of the busbar body 1.
[0029] In this embodiment of the utility model, the purpose of this arrangement is that the multi-layer socket assembly 3 ensures that after the busbar body 1 is used in a new energy vehicle, it will not be damaged by cracking or separation after bending, twisting or other operations, so that the busbar body 1 has good strength and protection.
[0030] Example 2:
[0031] Please see Figures 1-3This embodiment provides a technical solution based on embodiment one: the isolation sleeve 36 is made of insulating rubber and is fitted onto the outer wall of the busbar body 1. Multiple thin copper conductors on the busbar body 1 are connected and fixed to each other by glue. The braided sleeve 35 is made of aramid fiber or polyester fiber as the main raw material. The braided sleeve 35 is lightweight and has high strength to increase tensile strength and protect the busbar body 1 from bending damage. The bending-resistant protective sleeve 34 is made of TPE thermoplastic elastomer or TPU thermoplastic polyurethane as the main raw material and has good bending resistance, friction resistance and tear resistance. The internal structure of the buffer layer 33 is a honeycomb support. The isolation strip 32 is mainly used to isolate the side wall of the outer insulating protective sleeve 31.
[0032] In this embodiment of the utility model, the purpose of this arrangement is to ensure that the isolation sleeve 36, the braided sleeve 35, the bend-resistant protective sleeve 34, the buffer layer 33 and the isolation strip 32 can fully protect the busbar body 1 by using suitable materials, thereby improving the overall performance and extending the service life.
[0033] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.
[0034] During operation, the busbar body 1 is made up of multiple thin copper conductors connected and fixed to each other with glue. The connection hole 2 is mainly used for connection with external electrical equipment. The busbar body 1 is mainly used in new energy vehicles. The isolation strip 32 is mainly used to isolate the side wall of the outer insulating protective sleeve 31. It has a sealing function for the buffer layer 33, the bending-resistant protective sleeve 34, the braided sleeve 35, and the isolation sleeve 36. The isolation sleeve 36 is made of insulating rubber and is fitted onto the outer wall of the busbar body 1. The braided sleeve 35 is made of aramid fiber or polyester fiber as the main raw material. The material is lightweight and has high strength to increase the tensile strength and protect the busbar body 1 from bending damage. The bending-resistant protective sleeve 34 is made of TPE thermoplastic elastomer or TPU thermoplastic polyurethane as the main raw material. It has good bending resistance, abrasion resistance and tear resistance. The internal structure of the buffer layer 33 is a honeycomb support, which can provide good support under external pressure.
[0035] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0036] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A laminated insulated flexible busbar for new energy vehicles, characterized in that: Includes a busbar body (1), the outer wall of which is equipped with a multi-layer socket assembly (3). The busbar body (1) is made of multiple anti-corona flat thin copper sheet conductors stacked together. Two connection holes (2) are opened on the left and right sides of the outer wall of the busbar body (1). The multi-layer sleeve assembly (3) includes an outer insulating protective sleeve (31), an isolation sleeve (36) is installed on the outer wall of the busbar body (1), a braided sleeve (35) is sleeved on the outer wall of the isolation sleeve (36), a bend-resistant protective sleeve (34) is installed on the outer wall of the braided sleeve (35), a buffer layer (33) is installed on the outer wall of the bend-resistant protective sleeve (34), the buffer layer (33) is fixedly connected to the inner wall of the outer insulating protective sleeve (31), and isolation strips (32) are fixedly installed on both sides of the outer insulating protective sleeve (31) and sleeved on the outer wall of the busbar body (1).
2. The new energy vehicle laminated insulated flexible busbar according to claim 1, characterized in that: The isolation sleeve (36) is made of insulating rubber and is fitted onto the outer wall of the busbar body (1). Multiple thin copper conductors on the busbar body (1) are connected and fixed to each other by glue.
3. The new energy vehicle laminated insulated flexible busbar according to claim 1, characterized in that: The braided sleeve (35) is made of a lightweight and high-strength material to increase tensile strength and protect the busbar body (1) from bending damage.
4. The new energy vehicle laminated insulated flexible busbar according to claim 1, characterized in that: The bend-resistant protective sleeve (34) has good bend resistance, abrasion resistance and tear resistance.
5. The new energy vehicle laminated insulated flexible busbar according to claim 1, characterized in that: The internal structure of the buffer layer (33) is a honeycomb support.
6. The new energy vehicle laminated insulated flexible busbar according to claim 1, characterized in that: The isolation strip (32) is mainly used to isolate the side wall of the outer insulating protective sleeve (31).