Elastic conductive copper bar structure with self-adapting function

Abstract

The utility model relates to the field of electrical connection, concretely relates to a kind of elastic conductive copper bar structure with self-adapting adjustment function, including conductive copper bar one and conductive copper bar two, the middle part of the conductive copper bar two is provided with elastic compensation section, the side of the conductive copper bar one and the conductive copper bar two mutually close is connected by connecting component, the connecting component includes connecting post and end face limit block, the end face limit block is fixedly connected in the upper and lower ends of connecting post, the side of the conductive copper bar one close to the conductive copper bar two is equipped with the limit guide groove one that is vertically arranged and penetrates the upper and lower surfaces of the conductive copper bar one. By being provided with omega-shaped elastic compensation section, so that the copper bar can absorb the axial thermal expansion or shrinkage caused by temperature change, reduce the influence of thermal stress on connecting point, avoid the connection loose or fracture phenomenon that traditional copper bar can appear, by setting connecting component, even under the condition of thermal expansion and contraction, can also maintain good electrical contact state.

Description

Technical Field

[0001] This utility model relates to the field of electrical connections, specifically to a flexible conductive copper busbar structure with adaptive adjustment function. Background Technology

[0002] In high-power electrical systems such as new energy vehicle battery packs, energy storage power station battery modules, and industrial high-power frequency converters, conductive copper busbars, as key current transmission components, undertake the core task of transmitting large currents of hundreds or even thousands of amperes between different electrical components. Their connection stability directly determines the overall operational safety and lifespan of the system.

[0003] Traditional rigid copper busbars typically employ an integrated rectangular copper bar structure, with both ends bolted to battery terminals, power module terminals, and other electrical components. When the system starts and stops or experiences load fluctuations, the Joule heat generated by the high current transmission of the copper busbar creates a cyclic temperature difference with changes in the external ambient temperature. This results in significant thermal expansion and contraction deformation along the length of the copper busbar (for example, a 100mm long copper busbar expands and contracts approximately 1.6mm for every 100°C temperature change). Since rigid copper busbars cannot compensate for this deformation independently, this deformation translates into tensile or compressive stress on the fixed points at both ends. Over time, this cycle can cause the connecting bolts to loosen, leading to gaps between the copper busbar and the terminal contact surface. This increases contact resistance, causes localized overheating, accelerates the aging of insulation components, and can even lead to safety accidents such as copper busbar ablation and battery thermal runaway.

[0004] Therefore, it is necessary to invent a flexible conductive copper busbar structure with adaptive adjustment function to solve the above problems. Utility Model Content

[0005] The purpose of this invention is to provide an elastic conductive copper busbar structure with adaptive adjustment function. By setting up an elastic compensation section and connecting components to work together, it can solve the problem in the prior art where the copper busbar loosens or breaks due to axial thermal expansion or contraction caused by temperature changes.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an elastic conductive copper busbar structure with adaptive adjustment function, comprising a conductive copper busbar one and a conductive copper busbar two, wherein an elastic compensation section is provided in the middle of the conductive copper busbar two, and the conductive copper busbar one and the conductive copper busbar two are connected by a connecting component on their adjacent sides, the connecting component comprising a connecting post and an end face limiting block, the end face limiting block being fixedly connected to the upper and lower ends of the connecting post, a limiting guide groove one penetrating the upper and lower surfaces and vertically arranged is provided on the side of the conductive copper busbar one near the conductive copper busbar two, and a limiting guide groove two penetrating the upper and lower surfaces and vertically arranged is provided on the side of the conductive copper busbar two near the conductive copper busbar one, the connecting post being simultaneously embedded in the limiting guide groove one and the limiting guide groove two and being able to slide along its length direction.

[0007] Preferably, both the first limiting guide groove and the second limiting guide groove extend along the length direction of the copper busbar.

[0008] Preferably, the end face limiting block is connected to the connecting column by brazing or cold pressing. The number of end face limiting blocks is set to at least two sets. The two sets of end face limiting blocks are respectively set at the upper end of the first conductive copper busbar and the lower side of the second conductive copper busbar. The distance between the two sets of end face limiting blocks is equal to the sum of the thicknesses of the first conductive copper busbar and the second conductive copper busbar.

[0009] Preferably, the conductive copper busbar one is provided with an integrally formed and vertically arranged folded section one on the side away from the conductive copper busbar two, and the surface of the folded section one is provided with mounting holes one that penetrate the left and right side surfaces of the folded section one.

[0010] Preferably, the right horizontal portion of the conductive copper busbar 2 is provided with a mounting hole 2 penetrating the upper and lower surfaces of the conductive copper busbar 2, and the side of the conductive copper busbar 2 away from the conductive copper busbar 1 is provided with an integrally formed and vertically arranged folded section 2, and the surface of the folded section 2 is provided with a mounting hole 3 penetrating the left and right surfaces of the folded section 2.

[0011] Preferably, the outer wall of the conductive copper busbar is covered with an insulating protective sleeve, and a lateral protrusion integrally formed is fixedly connected to one side wall of the conductive copper busbar.

[0012] The technical effects and advantages provided by this utility model in the above technical solution are as follows: This invention features an Ω-shaped elastic compensation section, enabling the copper busbar to absorb axial thermal expansion or contraction caused by temperature changes. This reduces the impact of thermal stress on the connection points and avoids the loosening or breakage that may occur with traditional copper busbars. By incorporating the connection components, good electrical contact can be maintained even under conditions of thermal expansion and contraction, thus reducing contact resistance. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0014] Figure 1 This is a three-dimensional structural diagram of the overall device in this utility model; Figure 2 This is a three-dimensional structural breakdown diagram of the overall device in this utility model; Figure 3 This is a three-dimensional structural breakdown diagram of the conductive copper busbar, connecting components, and insulating protective sleeve in this utility model.

[0015] Legend: 11. Conductive copper busbar one; 12. Lateral protrusion; 13. Folded section one; 14. Mounting hole one; 21. Conductive copper busbar two; 22. Elastic compensation section; 23. Mounting hole two; 24. Folded section two; 25. Mounting hole three; 3. Connecting assembly; 31. Connecting post; 32. End face limiting block; 33. Limiting guide groove one; 34. Limiting guide groove two; 4. Insulating protective sleeve. Detailed Implementation

[0016] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0017] This utility model provides, for example Figure 1 - Figure 3 The diagram illustrates a flexible conductive copper busbar structure with adaptive adjustment function, comprising a first conductive copper busbar 11 and a second conductive copper busbar 21. Both are made of high-purity oxygen-free copper and are rectangular strip-shaped plates designed to carry high current transmission. The outer wall of the first conductive copper busbar 11 is covered with an insulating protective sleeve 4. An integrally formed lateral protrusion 12 is fixedly connected to the side wall of the first conductive copper busbar 11 to limit the displacement of the insulating protective sleeve 4 and improve its installation stability. The second conductive copper busbar 21 has an elastic compensation section 22 in its middle, made of an elastic copper alloy. The elastic compensation section 22 is Ω-shaped, giving the copper busbar axial expansion and contraction capability. It can absorb thermal expansion displacement within a range of ±15mm and reduce internal stress caused by temperature changes. The Ω-shaped corrugation radius of the elastic compensation section 22 is 8-12mm, the thickness is 2.5-3.5mm, and its elastic modulus is 90-105GPa. It has excellent fatigue life and resilience under repeated thermal expansion and contraction conditions. The conductive copper busbar 11 and the conductive copper busbar 21 are connected on their adjacent sides by the connecting component 3, which is used to provide adaptive adjustment space for the deformation caused by thermal expansion and contraction of the copper busbar.

[0018] like Figure 2 and Figure 3 As shown, the connecting component 3 includes a connecting post 31 and an end face limiting block 32. The end face limiting block 32 is fixedly connected to the upper and lower ends of the connecting post 31. A limiting guide groove 33 is provided on the side of the conductive copper busbar 11 near the conductive copper busbar 21, penetrating the upper and lower surfaces of the conductive copper busbar 11 and arranged vertically. A limiting guide groove 34 is provided on the side of the conductive copper busbar 21 near the conductive copper busbar 11, penetrating the upper and lower surfaces of the conductive copper busbar 21 and arranged vertically. Both the limiting guide groove 33 and the limiting guide groove 34 extend along the length of the copper busbar, and the groove width is slightly larger than the diameter of the connecting post 31, with a reserved sliding gap of 0.1 to 0.5 mm to ensure smooth sliding while limiting lateral displacement. The connecting post 31 is simultaneously embedded in the limiting guide groove 33 and the limiting guide groove 34 and can slide along its length.

[0019] like Figure 2 and Figure 3 As shown, the end face limiting block 32 is connected to the connecting post 31 by brazing or cold pressing. The number of end face limiting blocks 32 is set to at least two sets. The two sets of end face limiting blocks 32 are respectively set at the upper end of the conductive copper busbar 11 and the lower side of the conductive copper busbar 21, and are used to axially limit the conductive copper busbar 11 and the conductive copper busbar 21. The distance between the two sets of end face limiting blocks 32 is equal to the sum of the thicknesses of the conductive copper busbar 11 and the conductive copper busbar 21, so that the conductive copper busbar 11 and the conductive copper busbar 21 are always in a pressed state at the connection, maintaining good electrical contact. The contact surfaces of the conductive copper busbar 11 and the conductive copper busbar 21 are both provided with a silver plating layer to further reduce the contact resistance of the contact surfaces.

[0020] like Figure 1 - Figure 3 As shown, a vertically oriented, integrally formed folded section 13 is provided on the side of the conductive copper busbar 11 away from the conductive copper busbar 21. Mounting holes 14, penetrating the left and right sides of the folded section 13, are provided on its surface for fixed connection with external equipment via bolts or rivets. Mounting holes 23, penetrating the upper and lower surfaces of the conductive copper busbar 21, are provided on the horizontal right side of the conductive copper busbar 21. A vertically oriented, integrally formed folded section 24 is provided on the side of the conductive copper busbar 21 away from the conductive copper busbar 11. Mounting holes 35, penetrating the left and right sides of the folded section 24, are provided on its surface. Through the combination of mounting holes 23 and 325, operators can select the appropriate mounting hole according to the height of the external equipment's wiring terminals and achieve a fixed connection via bolts or rivets, eliminating the need for additional adapters and improving installation applicability.

[0021] The working principle of this utility is as follows: When the equipment is powered on, the temperature of the conductive copper busbar rises due to the Joule heat generated by the current passing through it, causing the material to undergo axial thermal expansion. Since conductive copper busbar 11 and conductive copper busbar 21 are connected to different electrical modules or brackets, their coefficients of thermal expansion or the degree of heating may differ, resulting in a relative displacement trend in the connection area.

[0022] When temperature changes cause the copper busbar to elongate or shorten, the elastic compensation section 22 is stretched or contracted, which can absorb thermal expansion displacement within a maximum range of ±15mm. This avoids tensile stress at the connection points between the two ends of the copper busbar and external equipment, preventing loosening of the connecting bolts or breakage of the copper busbar. At the same time, the conductive copper busbar 11 and the conductive copper busbar 21 move closer to each other on one side through the connecting assembly 3 to achieve adaptive adjustment. The connecting post 31 in the connecting assembly is embedded in the limiting guide groove 33 of the conductive copper busbar 11 and the limiting guide groove 34 of the conductive copper busbar 21. When the copper busbar expands or contracts due to thermal expansion and contraction, the connecting post 31 can slide smoothly along the length direction of the guide groove. This ensures smooth sliding and limits the lateral displacement of the copper busbar perpendicular to the current transmission direction, preventing misalignment of the copper busbar from reducing the contact area.

[0023] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A flexible conductive copper busbar structure with adaptive adjustment function, comprising conductive copper busbar one (11) and conductive copper busbar two (21), characterized in that: The conductive copper busbar 2 (21) is provided with an elastic compensation section (22) in the middle. The elastic compensation section (22) is Ω-shaped. The conductive copper busbar 1 (11) and the conductive copper busbar 2 (21) are connected by a connecting component (3) on their respective sides. The connecting component (3) includes a connecting post (31) and an end face limiting block (32). The end face limiting block (32) is fixedly connected to the upper and lower ends of the connecting post (31). The conductive copper busbar 1 (11) is provided with a limiting guide groove 1 (33) that penetrates the upper and lower surfaces of the conductive copper busbar 1 (11) and is vertically arranged on its side. The conductive copper busbar 2 (21) is provided with a limiting guide groove 2 (34) that penetrates the upper and lower surfaces of the conductive copper busbar 2 (21) and is vertically arranged on its side. The connecting post (31) is simultaneously embedded in the limiting guide groove 1 (33) and the limiting guide groove 2 (34) and can slide along its length direction.

2. The elastic conductive copper busbar structure with adaptive adjustment function according to claim 1, characterized in that: Both the limiting guide groove one (33) and the limiting guide groove two (34) extend along the length direction of the copper busbar.

3. The elastic conductive copper busbar structure with adaptive adjustment function according to claim 1, characterized in that: The end face limiting block (32) is connected to the connecting column (31) by brazing or cold pressing. The number of the end face limiting blocks (32) is set to at least two sets. The two sets of end face limiting blocks (32) are respectively set at the upper end of the first conductive copper busbar (11) and the lower side of the second conductive copper busbar (21). The distance between the two sets of end face limiting blocks (32) is equal to the sum of the thicknesses of the first conductive copper busbar (11) and the second conductive copper busbar (21).

4. The elastic conductive copper busbar structure with adaptive adjustment function according to claim 1, characterized in that: The conductive copper busbar 1 (11) is provided with an integrally formed and vertically arranged folding section 1 (13) on the side away from the conductive copper busbar 2 (21). The surface of the folding section 1 (13) is provided with mounting holes 1 (14) that penetrate the left and right sides of the folding section 1 (13).

5. The elastic conductive copper busbar structure with adaptive adjustment function according to claim 1, characterized in that: The right horizontal portion of the conductive copper busbar 2 (21) is provided with mounting holes 2 (23) that penetrate the upper and lower surfaces of the conductive copper busbar 2 (21). The conductive copper busbar 2 (21) is provided with an integrally formed and vertically arranged folded section 2 (24) on the side away from the conductive copper busbar 1 (11). The surface of the folded section 2 (24) is provided with mounting holes 3 (25) that penetrate the left and right surfaces of the folded section 2 (24).

6. The elastic conductive copper busbar structure with adaptive adjustment function according to claim 1, characterized in that: The outer wall of the conductive copper busbar (11) is covered with an insulating protective sleeve (4), and the side wall of the conductive copper busbar (11) is fixedly connected with an integrally formed lateral protrusion (12).

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