A flexible power connection structure

Abstract

The utility model discloses a kind of flexible power connection structures, adopt hard copper bar and connect external device through connector, keep good conductivity and structural rigidity, by introducing soft copper bar on the basis of hard copper bar to constitute flexible connection structure, realize and the flexible connection of power module inside controller, can be flexibly adjusted to the connection direction according to actual installation demand, improve installation flexibility, simultaneously, flexible connection structure can effectively absorb the mechanical stress caused by installation error in installation process, reduce the fatigue damage risk of connection structure, avoid the fracture or contact bad caused by stress concentration, enhance the system reliability, prolong service life, in addition, by the flexible adjustment function of soft copper bar, reduce the requirement of designing multiple hard copper bars due to different installation directions, reduce the type of hard copper bar, improve product modularization and standardization degree, and do not need to install additional adapter, simplify assembly process, improve the production efficiency of product.

Description

Technical Field

[0001] This utility model belongs to the field of circuit connection technology, and relates to copper busbar flexible connection technology, specifically a flexible power connection structure. Background Technology

[0002] In applications such as industrial power control, new energy vehicles, and energy storage systems, controllers, as critical power control units, often need to meet IP67 or higher protection standards to withstand harsh conditions such as humidity, dust, and vibration, ensuring long-term operational reliability. Currently, these controllers commonly use rigid copper busbars as power interface components. This connection method has advantages such as high conductivity and good mechanical strength, and has become the standard configuration for most controller products. However, existing rigid copper busbar connection solutions still have the following technical limitations:

[0003] Rigid structures lead to poor installation adaptability: Hard copper busbars are rigid components and cannot be flexibly adjusted according to the installation angle or spatial layout on site. In directionally restricted or non-standard installation scenarios, adapter copper busbars or transitional structural components are often required, which not only increases system complexity and material costs, but also increases assembly difficulty.

[0004] Alignment errors can easily introduce mechanical stress: Due to the lack of flexible compensation capabilities, if installation alignment deviations occur during assembly, the rigid copper busbar cannot effectively absorb the errors, leading to localized stress concentration at the connection points. Under long-term operation, this may cause material fatigue or even cracking, resulting in increased contact resistance and decreased connection reliability.

[0005] Poor maintainability and replaceability: The rigid connection structure is difficult to disassemble. If it is necessary to replace the controller or repair the power circuit, the operation is cumbersome and may damage adjacent components, which reduces the overall maintainability of the equipment and the efficiency of field service.

[0006] Diverse specifications lead to structural redundancy: In order to adapt to different installation directions or interface layouts, it is often necessary to develop a variety of hard copper busbar variants, which generates additional mold opening, inventory and management costs, which is not conducive to product serialization and cost control. Utility Model Content

[0007] To address the technical problems existing in the background art, this utility model proposes a flexible power connection structure. By introducing a soft copper busbar welding structure on the basis of traditional hard copper busbar, the connection direction can be flexibly adjusted, thereby improving installation flexibility and system reliability.

[0008] This utility model proposes a flexible power connection structure, including: a hard copper busbar, a connector, and a soft copper busbar. One end of the hard copper busbar is rigidly connected to the connector to connect to an external device through the connector. The other end of the hard copper busbar is fixedly connected to the soft copper busbar to flexibly connect to the power module inside the controller through the soft copper busbar.

[0009] Furthermore, the soft copper busbar is made of multiple layers of copper foil stacked on top of each other, and has flexibility and electrical conductivity.

[0010] Furthermore, the soft copper busbar is curved in a "C" shape or in an "S" shape.

[0011] Furthermore, one end of the soft copper busbar is fixedly connected to the hard copper busbar by welding, and the other end of the soft copper busbar has at least one mounting hole for connection to the power module inside the controller by bolts.

[0012] Furthermore, the outer surface of the connection between the soft copper busbar and the hard copper busbar is covered with an insulating protective layer.

[0013] Furthermore, the insulating protective layer adopts heat shrink tubing, silicone sleeve, or integral potting structure.

[0014] Furthermore, the hard copper busbar is inserted into the connector's connecting slot and rigidly connected to the connector, and a sealing ring is fitted inside the connecting slot for connection and sealing.

[0015] The flexible power connection structure provided by this utility model uses a rigid copper busbar and connects to external devices through connectors, maintaining good conductivity and structural rigidity. By introducing a soft copper busbar on the basis of the rigid copper busbar to form a flexible connection structure, a flexible connection with the internal power module of the controller can be achieved. The connection direction can be flexibly adjusted according to actual installation requirements, improving installation flexibility. At the same time, the flexible connection structure can effectively absorb the mechanical stress caused by installation errors during the installation process, reduce the risk of fatigue damage to the connection structure, avoid fracture or poor contact caused by stress concentration, enhance system reliability, and extend service life. In addition, the flexible adjustment function of the soft copper busbar reduces the need to design multiple rigid copper busbars for different installation directions, reduces the types of rigid copper busbars, improves the modularity and standardization of the product, and eliminates the need for additional adapters, simplifying the assembly process and improving product production efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this utility model.

[0017] Figure 2 This is a schematic diagram of the welding of the hard copper busbar and the soft copper busbar of this utility model. Detailed Implementation

[0018] 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 skilled in the art without creative effort are within the protection scope of the present utility model.

[0019] like Figure 1-2 As shown, this utility model provides a flexible power connection structure, including: a hard copper busbar 1, a connector 2, and a soft copper busbar 3;

[0020] One end of the hard copper busbar 1 is rigidly connected to the connector 2 to connect to external devices through the connector 2, while maintaining good conductivity and structural rigidity;

[0021] The soft copper busbar 3 is made of multiple layers of copper foil stacked on top of each other, and has good flexibility and conductivity.

[0022] The other end of the hard copper busbar 1 is fixedly connected to the soft copper busbar 3 so as to flexibly connect to the power module inside the controller through the soft copper busbar 3.

[0023] By connecting a soft copper busbar 3 to the end of the hard copper busbar 1 to form a flexible connection structure, the connection direction can be flexibly adjusted according to actual installation requirements, improving installation flexibility. At the same time, the flexible connection structure can effectively absorb mechanical stress caused by installation errors during installation, reduce the risk of fatigue damage to the connection structure, avoid breakage or poor contact due to stress concentration, enhance system reliability, and extend service life. In addition, the flexible adjustment function of the soft copper busbar 3 reduces the need to design multiple hard copper busbars 1 for different installation directions, reduces the types of hard copper busbars 1, improves the modularity and standardization of the product, and eliminates the need for additional adapters, simplifying the assembly process and improving product production efficiency.

[0024] Specifically, the soft copper busbar 3 is bent in a "C" shape or an "S" shape, and can be flexibly bent according to the actual installation direction of the power module inside the controller to adapt to the installation requirements of the controller with different angles or limited space.

[0025] One end of the soft copper busbar 3 is fixedly connected to the hard copper busbar 1 by welding. The welding part is brazed or laser welded with high conductivity solder to ensure the mechanical strength and conductivity of the connection. The other end of the soft copper busbar 3 has at least one mounting hole 31 for connecting to the power module inside the controller by bolts. This realizes the detachable connection of the soft copper busbar 3, which facilitates later maintenance and replacement and improves the maintainability of the system.

[0026] The outer surface of the connection between the soft copper busbar 3 and the hard copper busbar 1 is covered with an insulating protective layer 4, which adopts a heat shrink tubing, silicone sleeve or integral potting structure.

[0027] Connector 2 can be an APTIV connector. The hard copper busbar 1 is inserted into the connecting groove 21 of connector 2 and rigidly connected to connector 2. A sealing ring 5 is adapted and installed in the connecting groove 21 for connection and sealing. Through the sealed protection design of the overall structure, it has good sealing and insulation performance, fully meets the IP67 protection level requirements, and is suitable for harsh environments such as outdoor, humid or dusty environments.

[0028] The above description is merely an example and illustration of the structure of this utility model. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the structure of the utility model or exceed the scope defined in the claims, they should all fall within the protection scope of this utility model.

Claims

1. A flexible power connection structure, characterized in that, include: Hard copper busbar (1), connector (2), soft copper busbar (3). One end of the hard copper busbar (1) is rigidly connected to the connector (2) to connect to external devices through the connector (2). The other end of the hard copper busbar (1) is fixedly connected to the soft copper busbar (3) to flexibly connect to the power module inside the controller through the soft copper busbar (3).

2. The connection structure according to claim 1, characterized in that, The soft copper busbar (3) is made of multiple layers of copper foil stacked on top of each other, and has flexibility and conductivity.

3. The connection structure according to claim 2, characterized in that, The soft copper busbar (3) is in a "C" shaped bend or an "S" shaped bend.

4. The connection structure according to claim 1, characterized in that, One end of the soft copper busbar (3) is fixedly connected to the hard copper busbar (1) by welding, and the other end of the soft copper busbar (3) has at least one mounting hole (31) for connecting to the power module inside the controller by bolts.

5. The connection structure according to claim 1, characterized in that, The outer surface of the connection between the soft copper busbar (3) and the hard copper busbar (1) is covered with an insulating protective layer (4).

6. The connection structure according to claim 5, characterized in that, The insulating protective layer (4) adopts heat shrink tubing, silicone sleeve or integral potting structure.

7. The connection structure according to claim 1, characterized in that, The hard copper busbar (1) is inserted into the connecting groove (21) of the connector (2) and rigidly connected to the connector (2). A sealing ring (5) is adapted to be installed in the connecting groove (21) for connection sealing.

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