A metal flexible copper bar device adapted to a specific device

Abstract

The utility model discloses a kind of metal soft copper bar devices suitable for specific equipment, including copper bar body, the copper bar body includes the fixed end connecting mechanism for being rigidly connected with the predetermined installation position of specific equipment, soft copper bar assembly and multiple degrees of freedom angle adjusting mechanism, one end of the soft copper bar assembly is connected fixed end connecting mechanism. Non-planar mounting surface can be precisely fitted, accurate alignment is realized through bolt fine adjustment, it is convenient to overhaul and maintain, multiple degrees of freedom mechanism allows soft copper bar to be flexibly rotated and swung within specified range, limit structure prevents damage caused by excessive adjustment, shock-absorbing wear-resistant bushing buffers equipment vibration, prolongs service life. Excellent conductivity and anti-interference performance, high-efficiency stable heat dissipation. Even in airtight environment, it can effectively dissipate heat through flow guide gap, ensure long-term stable operation of copper bar, meet the demand of new energy, industrial frequency converter and other high-power equipment.

Description

Technical Field

[0001] This utility model relates to the field of copper busbar technology, specifically a metal soft copper busbar device adapted to specific equipment. Background Technology

[0002] As a key conductive connector in high-power applications such as new energy equipment and industrial control cabinets, the reliability, adaptability, and operational stability of metal flexible copper busbars directly affect equipment performance. However, existing metal flexible copper busbars have significant technical drawbacks: First, poor installation adaptability; they are difficult to fully fit on non-planar mounting surfaces of specific equipment, often requiring forced grinding and adjustment, and the hole alignment accuracy is low, making disassembly and maintenance inconvenient. Second, rigid angle adjustment; lacking a flexible adjustment structure, forcibly bending to adapt to the installation angle can easily lead to copper fatigue fracture or insulation layer cracking, shortening service life. Third, insufficient conductivity and heat dissipation performance; ordinary copper busbars have high impedance, resulting in significant Joule heat loss during high current transmission, and the simple heat dissipation structure makes it difficult to dissipate heat in the enclosed environment of the equipment, easily leading to conductivity degradation or high-temperature aging of the insulation layer. Utility Model Content

[0003] In order to overcome the shortcomings of existing technical solutions, this utility model provides a metal soft copper busbar device adapted to specific equipment, which can effectively solve the problems raised in the background art.

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

[0005] A flexible copper busbar device adapted to a specific device includes a copper busbar body, the copper busbar body including a fixed end connection mechanism for rigidly connecting to a predetermined installation position of the specific device, a flexible copper busbar assembly, and a multi-degree-of-freedom angle adjustment mechanism, one end of the flexible copper busbar assembly being connected to the fixed end connection mechanism;

[0006] The multi-degree-of-freedom angle adjustment mechanism is located at the connection between the fixed end connection mechanism and the soft copper busbar assembly. The multi-degree-of-freedom angle adjustment mechanism includes an axial rotation limiting part and a radial swing limiting part, allowing the soft copper busbar assembly to rotate axially and swing radially relative to the fixed end connection mechanism within a preset angle range.

[0007] The outer surface of the soft copper busbar assembly is provided with an integrated heat dissipation structure. The integrated heat dissipation structure includes a thermally conductive insulating layer covering the multi-strand soft copper wire bundle and a heat dissipation fin array attached to the outer surface of the thermally conductive insulating layer. The heat dissipation fin array is distributed in segments along the length direction of the copper busbar body.

[0008] As a further description of the above technical solution, the fixed end connection mechanism includes a base and an adjustable fixing plate. The base is provided with a curved surface or stepped surface that matches the mounting surface of a specific device. The adjustable fixing plate is detachably fixed to the base by locking bolts.

[0009] As a further description of the above technical solution, the adjustable fixing plate is provided with an elastic conductive pad and an electromagnetic shielding layer on the side facing the equipment mounting surface. The elastic conductive pad is a composite layer with embedded silicone conductive particles.

[0010] As a further description of the above technical solution, the axial rotation limiting part is composed of a slot provided on the fixed end connecting mechanism and a turntable with a limiting protrusion fixed to the end of the soft copper busbar assembly.

[0011] The radial swing limiting part consists of a ball joint and an open limiting sleeve that constrains its swing angle. The ball part of the ball joint is fixedly connected to the center of the turntable, and one end of the ball joint extends into the soft copper busbar assembly as a guide core.

[0012] As a further description of the above technical solution, the opening angle range of the opening limiting sleeve is ±30° to ±60°, and the inner wall of the opening limiting sleeve is fitted with a shock-absorbing and wear-resistant bushing.

[0013] As a further description of the above technical solution, the soft copper busbar assembly adopts a layered composite structure, including:

[0014] The inner layer is a silver-plated, high-conductivity soft copper busbar;

[0015] The middle layer is a ceramicized silicone rubber insulating layer;

[0016] The outer layer is a metal woven shielding mesh;

[0017] The thermally conductive insulating layer is wrapped around the outside of the metal woven shielding mesh.

[0018] As a further description of the above technical solution, a flow guiding gap is provided between adjacent heat dissipation fin arrays, and the surface of the heat dissipation fins is subjected to anodizing treatment to form a heat dissipation enhanced coating.

[0019] Compared with the prior art, the beneficial effects of this utility model are:

[0020] The present invention provides a metal soft copper busbar device adapted to specific equipment, which has at least one of the following beneficial effects during use:

[0021] The curved or stepped surface of the base can precisely fit non-planar mounting surfaces. Adjustable mounting plates achieve precise hole alignment through bolt fine-tuning. The detachable design facilitates inspection and maintenance. Elastic conductive gaskets can compensate for mounting surface errors of 0.1-0.5mm, preventing localized overheating or sudden increases in conductivity resistance caused by poor contact. Flexible and durable angle adjustment: The multi-degree-of-freedom mechanism allows the soft copper busbar to rotate and swing flexibly within a range of ±30° to ±60°. A limiting structure prevents damage caused by over-adjustment, and shock-absorbing and wear-resistant bushings buffer equipment vibration, extending service life. Excellent conductivity and anti-interference performance: Silver-plated high-conductivity copper busbars reduce high-current transmission losses. A ceramicized silicone rubber insulation layer is high-temperature resistant and short-circuit resistant, while a metal braided shielding mesh isolates electromagnetic interference. Efficient and stable heat dissipation: The integrated heat dissipation structure increases the heat dissipation area by 3-5 times and improves efficiency by more than 40%, keeping the temperature below 60℃. Even in enclosed environments, effective heat dissipation is achieved through the flow-guiding gaps, ensuring long-term stable operation of the copper busbar and meeting the needs of high-power equipment such as new energy and industrial frequency converters. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of a metal soft copper busbar device adapted to specific equipment according to this utility model;

[0023] Figure 2 This is a top view of a metal soft copper busbar device adapted to specific equipment according to the present invention.

[0024] Figure 3 This is a schematic diagram of the end structure of a metal soft copper busbar device adapted to a specific device according to the present invention;

[0025] Figure 4 This is a partial perspective structural diagram of a metal soft copper busbar device adapted to specific equipment according to this utility model.

[0026] Numbering on the map:

[0027] 1. Fixed end connection mechanism; 101. Base; 102. Adjustable fixing plate; 103. Locking bolt; 104. Elastic conductive gasket; 2. Multi-degree-of-freedom angle adjustment mechanism; 201. Axial rotation limiting part; 202. Radial swing limiting part; 203. Turntable; 204. Limiting sleeve with opening; 205. Slot; 206. Ball joint; 3. Soft copper busbar assembly; 301. Outer layer; 302. Middle layer; 303. Inner layer; 4. Integrated heat dissipation structure; 401. Heat dissipation fin array; 402. Enhanced heat dissipation coating. Detailed Implementation

[0028] 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.

[0029] like Figure 1-4 As shown, this utility model provides a metal flexible copper busbar device adapted to a specific device, including a copper busbar body. The copper busbar body includes a fixed end connection mechanism 1 for rigid connection with a predetermined installation position of the specific device, a flexible copper busbar assembly 3, and a multi-degree-of-freedom angle adjustment mechanism 2. One end of the flexible copper busbar assembly 3 is connected to the fixed end connection mechanism 1.

[0030] The fixed end, "base 101", is pre-designed with a curved or stepped surface that matches the mounting surface of a specific device, ensuring that the base 101 fits perfectly with the mounting surface (solving the fitting problem in non-planar installation scenarios). The adjustable fixing plate 102 is detachably fixed to the base 101 by locking bolts 103, and the position of the fixing plate can be finely adjusted according to the mounting hole position of the device to achieve "precise alignment and quick locking".

[0031] The multi-degree-of-freedom angle adjustment mechanism 2 is located at the connection between the fixed end connection mechanism 1 and the soft copper busbar assembly 3. The multi-degree-of-freedom angle adjustment mechanism 2 includes an axial rotation limiting part 201 and a radial swing limiting part 202, which allows the soft copper busbar assembly 3 to rotate axially and swing radially relative to the fixed end connection mechanism 1 within a preset angle range.

[0032] The adjustable mounting plate 102 is equipped with an "elastic conductive pad 104 (a composite layer with embedded silicone conductive particles)" and an "electromagnetic shielding layer" on the side facing the equipment. The elastic pad can compensate for minor flatness errors of the mounting surface and ensure a tight fit between the metal contact surfaces (avoiding conductive loss caused by poor contact). The electromagnetic shielding layer forms a closed shielding space to block external electromagnetic interference from entering the copper busbar and prevent the electromagnetic field radiation of the copper busbar itself from affecting the surrounding equipment.

[0033] The outer surface of the soft copper busbar assembly 3 is provided with an integrated heat dissipation structure 4. The integrated heat dissipation structure 4 includes a thermally conductive insulating layer covering the multi-strand soft copper wire bundle and a heat dissipation fin array 401 attached to the outer surface of the thermally conductive insulating layer. The heat dissipation fin array 401 is distributed in segments along the length direction of the copper busbar body.

[0034] The soft copper busbar assembly 3 is covered with a "thermally conductive and insulating layer"—this layer combines high thermal conductivity with insulation, enabling rapid heat transfer from the soft copper busbar (especially the Joule heat generated by the silver plating layer) to the outside. The integrated heat dissipation structure 4 (thermally conductive and insulating layer + segmented fin array) has a heat dissipation area 3-5 times larger than that of finless copper busbars. Combined with the flow-guiding gap and anodized coating, the heat dissipation efficiency can be improved by more than 40% (depending on the ambient temperature). Efficient heat dissipation can control the operating temperature of the copper busbar below 60℃ (in typical high-current scenarios), preventing the copper busbar from experiencing conductivity degradation due to overheating (the resistivity of copper increases with temperature) or the insulation layer from failing due to long-term high-temperature aging. Even in scenarios where the equipment is enclosed and air circulation is poor, the segmented fins and flow-guiding gap design can still achieve heat dissipation through limited air convection, solving the problem of "difficult heat dissipation" in traditional copper busbars in enclosed environments.

[0035] Furthermore, the fixed end connection mechanism 1 includes a base 101 and an adjustable fixing plate 102. The base 101 is provided with a curved surface or stepped surface that matches the mounting surface of a specific device. The adjustable fixing plate 102 is detachably fixed to the base 101 by locking bolts 103.

[0036] The curved / stepped surface design of the base 101 can precisely match the non-planar mounting surface of specific equipment. The adjustable fixing plate 102 achieves hole alignment through bolt fine-tuning, solving the problem of "the mounting surface not fitting and requiring forced grinding" in traditional copper busbars. The detachable design of the locking bolt 103 facilitates the disassembly and assembly of copper busbars during later equipment maintenance, reducing maintenance costs.

[0037] Furthermore, the adjustable fixing plate 102 is provided with an elastic conductive pad 104 and an electromagnetic shielding layer on the side facing the equipment mounting surface. The elastic conductive pad 104 is a composite layer embedded with silicone conductive particles. The flexibility of the elastic conductive pad 104 can compensate for minor flatness errors of the mounting surface (such as 0.1-0.5mm protrusions / depressions), ensuring 100% fit of the metal contact surfaces and avoiding "local overheating" or "sudden increase in conductive resistance" caused by poor contact.

[0038] Furthermore, the axial rotation limiting part 201 is composed of a slot 205 provided on the fixed end connecting mechanism 1 and a turntable 203 with a limiting protrusion fixed to the end of the soft copper busbar assembly 3.

[0039] The axial rotation limiting part 201 is composed of a "base 101 slot 205" and a "turntable 203 with limiting protrusion at the end of the soft copper busbar" - when the turntable 203 rotates around the axial direction with the soft copper busbar, the protrusion slides along the slot 205, and the length / arc of the slot 205 limits the rotation angle (to prevent excessive rotation from causing wire kinking or insulation damage).

[0040] The radial swing limiting part 202 is composed of a ball joint 206 and an open limiting sleeve 204 that restricts its swing angle. The ball part of the ball joint 206 is fixedly connected to the center of the turntable 203, and one end of the ball joint 206 extends into the soft copper busbar assembly 3 as a guide core.

[0041] The ball joint 206 has its ball portion fixed to the center of the turntable 203, while the other end extends into the interior of the flexible copper busbar as a "current guide" (serving both angle adjustment and current conduction functions). The opening angle range of the limiting sleeve 204 is ±30° to ±60°, constraining the swing amplitude of the ball joint; at the same time, the inner wall of the limiting sleeve is fitted with a "vibration-damping and wear-resistant bushing" to reduce frictional loss between the ball joint and the sleeve, and to buffer the impact of equipment vibration on the angle adjustment structure. The multi-degree-of-freedom angle adjustment mechanism 2 allows the flexible copper busbar to swing / rotate flexibly within a preset range, without the need to forcibly bend the copper busbar (forcibly bending traditional hard copper busbars can easily lead to fatigue fracture of the copper material or cracking of the insulation layer), significantly extending the service life of the copper busbar.

[0042] Furthermore, the opening angle range of the opening-type limiting sleeve 204 is ±30° to ±60°, and the inner wall of the opening-type limiting sleeve 204 is fitted with a shock-absorbing and wear-resistant bushing. The shock-absorbing and wear-resistant bushing can buffer vibrations during equipment operation (such as the periodic vibrations of motors, compressors, etc.), prevent the angle adjustment structure from loosening or wearing due to long-term vibration, and improve the reliability of the device in dynamic environments.

[0043] Furthermore, the soft copper busbar assembly 3 adopts a layered composite structure, including:

[0044] The intermediate layer 302 is a ceramicized silicone rubber insulating layer;

[0045] The outer 301 layer is a metal woven shielding mesh;

[0046] The inner 303 layer is a silver-plated, high-conductivity flexible copper busbar. This silver-plated, high-conductivity flexible copper busbar significantly reduces Joule heat loss during high-current transmission, making it suitable for high-power applications such as new energy equipment and industrial frequency converters. Even if the copper busbar experiences localized high temperatures due to a short circuit, it maintains its insulation performance, preventing the short circuit from escalating. It effectively isolates the copper busbar from external electromagnetic interference and prevents radiation interference from the copper busbar to surrounding sensitive components.

[0047] The thermally conductive insulating layer is wrapped around the outside of the metal woven shielding mesh.

[0048] The ball joint 206 extends into a "current guide core" which is directly connected to the inner 303 silver-plated copper busbar. Current is transmitted from the device end through the elastic conductive pad 104 → base 101 → turntable 203 → current guide core → silver-plated copper busbar to the other end of the device, forming a complete and low-loss conductive path.

[0049] Furthermore, the heat dissipation fin array 401 is provided with flow guiding gaps between adjacent fins, and the surface of the heat dissipation fins is anodized to form a heat dissipation enhanced coating 402.

[0050] The segmented distribution avoids airflow obstruction caused by excessively dense fins, while also accommodating the flexible shape of the copper busbars (the segmented sections can slightly deform with the bending of the copper busbars). "Guiding gaps" are provided between the fins, forming air convection channels: natural wind or airflow from equipment cooling fans can pass through the gaps and accelerate heat exchange on the fin surface. The fin surface undergoes "anodization treatment" to form a reinforced heat dissipation coating 402—the oxide layer improves the thermal conductivity and surface emissivity of the fins (enhancing thermal radiation capacity), further accelerating heat dissipation into the air.

[0051] 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 device adapted to specific equipment, characterized in that: The copper busbar body includes a fixed end connection mechanism for rigidly connecting to a predetermined installation position of a specific device, a flexible copper busbar assembly, and a multi-degree-of-freedom angle adjustment mechanism, wherein one end of the flexible copper busbar assembly is connected to the fixed end connection mechanism. The multi-degree-of-freedom angle adjustment mechanism is located at the connection between the fixed end connection mechanism and the soft copper busbar assembly. The multi-degree-of-freedom angle adjustment mechanism includes an axial rotation limiting part and a radial swing limiting part, allowing the soft copper busbar assembly to rotate axially and swing radially relative to the fixed end connection mechanism within a preset angle range. The outer surface of the soft copper busbar assembly is provided with an integrated heat dissipation structure. The integrated heat dissipation structure includes a thermally conductive insulating layer covering the multi-strand soft copper wire bundle and a heat dissipation fin array attached to the outer surface of the thermally conductive insulating layer. The heat dissipation fin array is distributed in segments along the length direction of the copper busbar body.

2. The metal soft copper busbar device adapted to specific equipment according to claim 1, characterized in that: The fixed end connection mechanism includes a base and an adjustable fixing plate. The base has a curved or stepped surface that matches the mounting surface of a specific device. The adjustable fixing plate is detachably fixed to the base by locking bolts.

3. The metal soft copper busbar device adapted to specific equipment according to claim 2, characterized in that: The adjustable fixing plate is provided with an elastic conductive pad and an electromagnetic shielding layer on the side facing the equipment mounting surface. The elastic conductive pad is a composite layer with embedded silicone conductive particles.

4. The metal soft copper busbar device adapted to specific equipment according to claim 1, characterized in that: The axial rotation limiting part consists of a slot provided on the fixed end connecting mechanism and a turntable with a limiting protrusion fixed to the end of the soft copper busbar assembly. The radial swing limiting part consists of a ball joint and an open limiting sleeve that constrains its swing angle. The ball part of the ball joint is fixedly connected to the center of the turntable, and one end of the ball joint extends into the soft copper busbar assembly as a guide core.

5. A metal soft copper busbar device adapted to specific equipment according to claim 4, characterized in that: The opening angle of the opening limiting sleeve is in the range of ±30° to ±60°, and the inner wall of the opening limiting sleeve is fitted with a shock-absorbing and wear-resistant bushing.

6. The metal soft copper busbar device adapted to specific equipment according to claim 1, characterized in that: The soft copper busbar assembly adopts a layered composite structure, including: The inner layer is a silver-plated, high-conductivity soft copper busbar; The middle layer is a ceramicized silicone rubber insulating layer; The outer layer is a metal woven shielding mesh; The thermally conductive insulating layer is wrapped around the outside of the metal woven shielding mesh.

7. A metal soft copper busbar device adapted to specific equipment according to claim 1, characterized in that: The heat dissipation fin array has flow guiding gaps between adjacent fins, and the surface of the heat dissipation fins is anodized to form a heat dissipation enhanced coating.

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