An injection molded soft copper bar connector

Abstract

The utility model discloses a kind of injection molding soft copper bar connectors, comprising: jack, injection molding shell and the soft copper bar formed by copper foil lamination;Soft copper bar both ends are pressed as conductive surface, and the conductive through hole that is formed with jack and carries out hard connection is formed on conductive surface;Soft copper bar middle part is equipped with cladding layer to form insulated flexible conductive row;Soft copper bar is integrally injection molded outside the junction of jack to form injection molding shell;Jack side is equipped with the process hole for injection molding, and the insulated contact finger in the injection molding shell is formed by the process hole to jack inside injection molding.The utility model soft copper bar both ends are pressed to form firm conductive surface, guarantee connection reliability;Middle part keeps unpressing state, give excellent deformation flexibility, adapt to complex installation environment.And the process hole of jack side has electroplating quality guarantee and injection molding glue inlet function, make insulated contact finger and shell one-off injection molding, simplify production process, improve sealing property and consistency.

Description

Technical Field

[0001] This utility model relates to the field of connector technology, specifically, to an injection-molded soft copper busbar connector. Background Technology

[0002] With the rapid development of the new energy and energy storage industries, the demand for capacity and quantity in battery PACK systems is increasing daily. Traditional wiring connectors often use wiring methods such as "U-shaped," "slanted," or "arc-shaped" in power interconnection. However, these connectors have obvious drawbacks:

[0003] 1. The tail protection component is relatively long and is not suitable for short-wire connection scenarios;

[0004] Second, the bending radius of cables is limited, especially with thicker wire diameters, which leads to an increase in cable length.

[0005] Third, the small gap between the plug and the battery pack panel during insertion makes it difficult to overcome surrounding structural obstacles, often requiring detour wiring, further increasing wire length and cost. These issues result in inconvenient operation, messy wiring, and higher costs in practical applications.

[0006] Therefore, this application proposes an injection-molded soft copper busbar connector to improve upon existing shortcomings. Utility Model Content

[0007] To address the aforementioned technical problems, the present invention aims to provide an injection-molded flexible copper busbar connector. This connector utilizes a flexible copper busbar composed of stacked copper foil sheets with central insulation as the conductive body, and conductive through-holes at both ends for rigid connection to the socket. The entire connector is then injection-molded into a single shell. This structure significantly improves flexibility while maintaining conductivity, effectively overcoming the limitations of cable bending radius and spatial obstacle crossing in traditional wiring, achieving a shorter, simpler, and lower-cost reliable connection.

[0008] The present invention solves the above problems through the following technical solution:

[0009] A molded flexible copper busbar connector includes: a socket, an injection-molded housing, and a flexible copper busbar formed by stacking copper foil sheets; the two ends of the flexible copper busbar are pressed together to form conductive surfaces, and conductive through holes are formed on the conductive surfaces to be rigidly connected to the socket; a covering layer is provided on the middle of the flexible copper busbar to form an insulating flexible conductive busbar; the connection between the flexible copper busbar and the socket is integrally injection molded to form an injection-molded housing; a process hole for injection molding is provided on the side of the socket, and an insulating contact finger inside the injection-molded housing is formed by injection molding through the process hole.

[0010] As a further improvement, the soft copper busbar has a bridging arc formed in the middle to avoid obstacles.

[0011] As a further improvement, the coating is formed by heat shrink tubing or overmolding in the middle of the soft copper busbar.

[0012] As a further improvement, the conductive through holes of the insulated flexible conductive busbar are rigidly connected to the sockets by screws, and the screws are used to lock the connection.

[0013] As a further improvement, the conductive through-hole of the insulated flexible conductive busbar and the socket step of the socket are subjected to interference fitting and then laser welding to achieve a hard connection.

[0014] As a further improvement, the process hole is located below the insulated flexible conductive busbar.

[0015] As a further improvement, the injection-molded shell is formed with a mating end and a connecting end, the mating end is fitted with a waterproof ring for external limiting, and the connecting end is fitted with a tail waterproof structure.

[0016] As a further improvement, the tail waterproof structure includes a soft waterproof sheath, within which a toothed structure is formed to mate with the injection-molded outer shell.

[0017] As a further improvement, the soft waterproof sheath is also provided with a toothed sealing body, which cooperates with the covering layer of the soft waterproof sheath and the insulating flexible conductive busbar to achieve waterproofing.

[0018] As a further improvement, the tail waterproof structure includes: an O-ring, a waterproof sealing wire body, and a tail cap. The waterproof sealing wire body is sleeved outside the covering layer of the insulated flexible conductive busbar and abuts against the end of the connection of the injection molded shell. The tail cap covers the covering layer of the insulated flexible conductive busbar, the waterproof sealing wire body, and the connection end of the injection molded shell. The connection end of the injection molded shell is provided with a groove for embedding the O-ring so that the O-ring is placed in the groove to seal the connection end of the tail cap and the injection molded shell.

[0019] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0020] (1) The two ends of the soft copper busbar of this utility model are pressed together to form a solid conductive surface, ensuring the reliability of the connection; the middle part is kept unpressed, giving it excellent deformation flexibility and adapting to complex installation environments.

[0021] (2) The conductive through hole of this utility model supports screw locking or laser welding, ensuring the mechanical strength and conductive stability of the electrical connection. In addition, the process hole on the side of the socket serves as both an electroplating quality assurance and an injection molding inlet, allowing the insulating contact finger and the shell to be injection molded in one piece, simplifying the production process and improving sealing and consistency.

[0022] (3) The dual-mode tail waterproof structure of this utility model can be selected according to the needs. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the copper foil structure of this utility model;

[0024] Figure 2 This is a schematic diagram of the soft copper busbar structure of this utility model;

[0025] Figure 3 A schematic diagram of the soft copper busbar of this utility model with a bridging arc;

[0026] Figure 4 This is a schematic diagram of the structure of the insulated flexible conductive bus of this utility model;

[0027] Figure 5 This is a schematic diagram showing the connection between the socket and the screw in this utility model.

[0028] Figure 6 This is a schematic diagram showing the connection between the socket and the socket step in this utility model.

[0029] Figure 7 This is a schematic diagram of the injection-molded housing structure of the present invention, showing the connection between the socket and the screw.

[0030] Figure 8 This is a schematic diagram of the injection-molded outer shell structure connecting the insertion hole and the insertion hole step of this utility model;

[0031] Figure 9 This is a schematic diagram of the structure of the soft waterproof sheath of this utility model;

[0032] Figure 10 This is a schematic diagram of the structure of the tail cap of this utility model.

[0033] Reference numerals: 1. Copper foil; 2. Flexible copper busbar; 201. Bridging arc; 202. Conductive surface; 203. Conductive through hole; 3. Insulating flexible conductive busbar; 4. Insertion hole; 401. Process hole; 402. Insertion hole step; 5. Screw; 6. Injection molded housing; 601. Insulating contact finger; 7. Soft waterproof sheath; 71. Toothed sealing body; 8. Waterproof ring; 9. O-ring; 10. Waterproof sealing body; 11. Tail cap. Detailed Implementation

[0034] 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.

[0035] Example:

[0036] Combined with appendix Figure 1-10 As shown, an injection-molded flexible copper busbar connector includes: a socket 4, an injection-molded shell, and a flexible copper busbar 2 formed by stacking copper foil 1. The two ends of the flexible copper busbar 2 are pressed together to form conductive surfaces 202, while the remaining parts are not pressed to ensure flexibility during deformation. Conductive through-holes 203 are formed on the conductive surfaces 202 for rigid connection with the socket 4. The flexible copper busbar of this connector is formed by stacking copper foil, and the thickness and width of individual copper foils and the entire flexible copper busbar are designed and selected according to current carrying requirements. The two ends of the flexible copper busbar are pressed together to form conductive surfaces and rigid connection with the socket, while the remaining parts are not pressed to ensure flexibility during deformation. Because the flexible copper busbar has a rectangular cross-section, compared to the circular cross-section of traditional conductors, the rectangular thickness is smaller than the circular diameter. Under the same cross-section, the flexible copper busbar has a smaller bending radius in the thickness direction than the circular diameter, making it more suitable for bending wiring in the thickness direction.

[0037] As a preferred option, the soft copper busbar 2 is selectively tooled to form the required bridging arc 201 according to the application scenario and bridging requirements, so as to avoid other components crossing the obstacle structure. The soft copper busbar 2 is first stacked flat, and then, according to the application scenario and bridging requirements, the required bridging arc 201 is selectively tooled to form.

[0038] The soft copper busbar 2 has a cladding layer in the middle to form an insulating flexible conductive busbar 3. Specifically, the soft copper busbar 2 is first heat-shrinkable tubing or undergoes initial encapsulation molding to form a cladding layer, thus forming the insulating flexible conductive busbar 3. The conductive through-hole 203 of the insulating flexible conductive busbar 3 is rigidly connected to the socket 4 by screws 5 to achieve locking. Optionally, the conductive through-hole 203 of the insulating flexible conductive busbar 3 can also be press-fitted to the socket step 402 of the socket 4 and then laser-welded. The side of the socket 4 is provided with a process hole 401 for electroplating and injection molding. The process hole is made at the root of the socket, which not only ensures the electroplating quality during the socket electroplating, but also serves as the injection port for the insulating contact finger of the molded socket. The insulating contact finger 601 inside the injection molded shell 6 is formed by injection molding through the process hole 401. When the socket 4 is connected to the insulating flexible conductive busbar 3, the process hole 401 is located below the insulating flexible conductive busbar 3. The sockets and soft copper busbars are secured with screws or laser-welded to ensure reliable conductivity, forming a copper busbar assembly.

[0039] After the insulated flexible conductive busbar 3 is connected to the socket 4, it is integrally injection molded to form the injection molded shell 6. The insulated contact finger 601 inside the injection molded shell 6 is formed in one step through the injection molding process hole 401. After the injection molding is completed, the injection molded shell has perpendicular mating ends and connecting ends. A waterproof ring 8 is installed on the outside of the mating ends of the injection molded shell 6 to limit the movement. A tail waterproof structure is installed at the end of the connecting end of the injection molded shell 6, i.e., the end of the covering layer.

[0040] Further technical solutions include two optional tail waterproof structures. One option is a separate soft waterproof sheath 7 with a toothed structure inside for mating with the injection-molded outer shell 6. Preferably, the soft waterproof sheath 7 also includes a toothed sealing wire 71, which mats with both the soft waterproof sheath 7 and the covering layer of the insulated flexible conductive busbar 3 to achieve waterproofing. The other option is a sealing structure consisting of an O-ring 9, a waterproof sealing wire 10, and a tail cap 11. The waterproof sealing wire 10 is fitted over the covering layer of the insulated flexible conductive busbar 3 and abuts against the tail of the injection-molded outer shell 6. The tail cap 11 covers the covering layer of the insulated flexible conductive busbar 3, the waterproof sealing wire 10, and the tail of the injection-molded outer shell 6 (i.e., the connecting end). The connecting end of the injection-molded outer shell 6 has a groove for embedding the O-ring 9, so that the O-ring 9 can be placed in the groove to seal the tail cap 11 and the tail of the injection-molded outer shell 6.

[0041] This utility model of injection-molded soft copper busbar connector achieves high current carrying capacity, high flexibility, high reliability connection, integrated insulation injection molding, and all-round waterproof protection through structural innovation and process integration.

[0042] Although the present invention has been described herein with reference to illustrative embodiments, the above embodiments are merely preferred embodiments of the present invention, and the implementation of the present invention is not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and implementations, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A type of injection-molded flexible copper busbar connector, characterized in that, include: The components include a socket, an injection-molded housing, and a flexible copper busbar made of stacked copper foil. The two ends of the flexible copper busbar are pressed together to form conductive surfaces, and conductive through holes that are rigidly connected to the socket are formed on the conductive surfaces. A cladding layer is provided in the middle of the flexible copper busbar to form an insulating flexible conductive busbar. The connection between the soft copper busbar and the socket is integrally injection molded to form an injection molded shell; the side of the socket is provided with a process hole for injection molding, through which the insulating contact finger inside the injection molded shell is formed by injection molding.

2. The injection-molded soft copper busbar connector according to claim 1, characterized in that, The soft copper busbar has a cross-arc structure in the middle to avoid obstacles.

3. The injection-molded soft copper busbar connector according to claim 1, characterized in that, The coating is formed by heat shrink tubing or overmolding in the middle of the soft copper busbar.

4. The injection-molded soft copper busbar connector according to claim 1, characterized in that, The conductive through-holes of the insulated flexible conductive busbar are rigidly connected to the sockets by screws, and the screws are used to lock the connection.

5. The injection-molded soft copper busbar connector according to claim 1, characterized in that, The conductive through-holes of the insulated flexible conductive busbar are press-fitted with the socket steps of the socket and then laser-welded to achieve a hard connection.

6. The injection-molded soft copper busbar connector according to claim 1, characterized in that, The process hole is located below the insulated flexible conductive busbar.

7. A molded soft copper busbar connector according to any one of claims 1-6, characterized in that, The injection-molded shell has a mating end and a connecting end. The mating end is fitted with a waterproof ring for external limiting, and the connecting end is fitted with a tail waterproof structure.

8. The injection-molded soft copper busbar connector according to claim 7, characterized in that, The tail waterproof structure includes a soft waterproof sheath, within which a toothed structure is formed to mate with the injection-molded outer shell.

9. The injection-molded soft copper busbar connector according to claim 8, characterized in that, The soft waterproof sheath also contains a toothed sealing element, which works in conjunction with the covering layers of the soft waterproof sheath and the insulated flexible conductive busbar to achieve waterproofing.

10. The injection-molded soft copper busbar connector according to claim 7, characterized in that, The tail waterproof structure includes an O-ring, a waterproof sealing wire, and a tail cap. The waterproof sealing wire is sleeved outside the insulating flexible conductive busbar and abuts against the end of the injection-molded shell. The tail cap covers the insulating flexible conductive busbar, the waterproof sealing wire, and the end of the injection-molded shell. The end of the injection-molded shell has a groove for embedding the O-ring so that the O-ring can be placed in the groove to seal the end of the tail cap and the injection-molded shell.

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