Copper wire array battery and large-current flexible bus

Abstract

The utility model relates to a kind of copper wire row battery and large-current flexible bus, and copper wire row battery is provided on large-current flexible bus.In the copper wire row battery, by setting the structure of the one-by-one superposition of several copper wire rows, and the setting mode of the cooperation insertion of contact protrusion and contact groove on each copper wire row (i.e. in the adjacent copper wire row, the contact protrusion of one copper wire row is one-to-one correspondingly inserted in the contact groove of another copper wire row, and contact protrusion is supported on contact surface), so that regular distribution gap space is formed between adjacent copper wire row.In this way, the effective heat dissipation area of copper wire row battery in unit volume is significantly increased, and the air circulation efficiency between the adhering surfaces is improved, so that the heat generated by current skin effect and resistance is efficiently dissipated, and the heat dissipation performance of the product is significantly improved.

Description

Technical Field

[0001] This utility model relates to the field of high-current flexible busbars, and particularly to copper wire busbar cores and high-current flexible busbars. Background Technology

[0002] In high-current transmission applications, two main conductor structures are commonly used: solid copper busbars and stranded cores of multiple round conductors. Solid copper busbars, with their integral rigid structure, offer advantages such as high mechanical strength and good installation stability, and are widely used in power distribution cabinets, industrial busbars, and new energy equipment. Stranded cores, on the other hand, increase conductor flexibility to adapt to the needs of complex wiring scenarios. While both technologies meet basic conductivity requirements, their physical structures have certain shortcomings when handling high current density transmission. Firstly, solid copper busbars have an overly compact and concentrated shape, which significantly limits the effective heat dissipation area (i.e., specific surface area) per unit volume, resulting in insufficient heat dissipation performance. Secondly, although the stranded wires slightly increase the surface contact through the stranding process, the tight stacking of the circular single wires still reduces the airflow efficiency and the actual heat dissipation capacity is still insufficient. Utility Model Content

[0003] This invention provides a copper wire busbar and a high-current flexible busbar, which can solve the problem of insufficient heat dissipation performance.

[0004] This utility model provides a copper wire busbar battery cell, which includes a plurality of copper wire busbars, and the copper wire busbars are stacked one by one. Each of the copper wire bars includes several conductive parts, each conductive part is arranged one by one along a straight line, and the central axes of each conductive part are parallel to each other in the length extension direction. The peripheral surfaces of each conductive part are connected in sequence to form a contact surface. Multiple contact protrusions are uniformly arranged on the contact surface, thereby forming a contact groove between every two adjacent contact protrusions. Between every two adjacent copper wire rows, each contact protrusion on one of the copper wire rows is inserted into a corresponding contact groove on the other copper wire row, and the contact protrusion abuts against the contact surface.

[0005] Preferably, the width of the contact protrusion is less than or equal to the interval between two adjacent contact protrusions.

[0006] Preferably, on each of the copper wire bars, the spacing between two adjacent contact protrusions is 1mm to 3mm; and / or The thickness of the copper wire busbar is 1.5mm to 5.5mm; and / or The width of the copper wire busbar is 20mm to 150mm.

[0007] Preferably, each of the copper wires has rounded corners at both ends along its length.

[0008] Preferably, the cross-section of the copper wire busbar is rectangular.

[0009] In another aspect, this utility model also provides a high-current flexible busbar, which includes the copper wire busbar core described in any of the above technical solutions. The high-current flexible busbar also includes an encapsulation assembly, which is sleeved on the outside of the copper wire busbar core.

[0010] Preferably, the encapsulation assembly includes a wrapping layer, an insulating layer, and a sheath layer; The wrapping layer is wound around the outside of the copper wire bus core, the insulating layer is sleeved on the outside of the wrapping layer, and the sheath layer is sleeved on the outside of the insulating layer.

[0011] Preferably, the wrapping layer includes a wrapping tape, which is tightly wrapped around the outside of the copper wire busbar to form the wrapping layer.

[0012] Preferably, the insulating layer comprises a polyvinyl chloride layer or a cross-linked polyethylene layer.

[0013] Preferably, the sheath layer comprises a silicone rubber sheath or a polyolefin sheath.

[0014] The following are the beneficial effects of implementing this utility model: This utility model relates to a copper wire busbar battery core and a high-current flexible busbar, wherein the high-current flexible busbar is provided with a copper wire busbar battery core. On this copper wire busbar battery core, by arranging a structure in which several copper wire busbars are stacked one on top of each other, and by configuring the contact protrusions and contact grooves on each copper wire busbar in a matching manner (i.e., between adjacent copper wire busbars, the contact protrusions of one copper wire busbar are correspondingly inserted into the contact grooves of another copper wire busbar, and the contact protrusions abut against the contact surface), a regularly distributed gap space is formed between adjacent copper wire busbars.

[0015] This significantly increases the effective heat dissipation area of ​​the copper wire busbar per unit volume, while also improving the airflow efficiency between the mating surfaces. This efficiently dissipates the heat generated by the skin effect and resistance, thereby significantly improving the product's heat dissipation performance. Attached Figure Description

[0016] The above and other objects, features and advantages of the present invention will become more apparent from the accompanying drawings, in which like reference numerals generally represent like parts.

[0017] Figure 1 This is a schematic diagram of the structure of the high-current flexible busbar in some embodiments of this utility model; Figure 2 This is another structural schematic diagram of the high-current flexible busbar in some embodiments of this utility model; Figure 3 yes Figure 2 Enlarged view at point A. Detailed Implementation

[0018] Embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. While embodiments of the present invention are shown in the drawings, it should be understood that the present invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention will be more thorough and complete, and will fully convey the scope of the present invention to those skilled in the art.

[0019] It should be understood that although the terms "first," "second," "third," etc., may be used in this invention to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this invention, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0020] In the description of this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0021] Unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0022] Figure 1The diagram illustrates a copper wire busbar core 10 in some embodiments of the present invention, comprising a plurality of copper wire busbars 1, which are stacked one on top of the other. Understandably, the copper wire busbar core 10 is used to form the core conductive structure of a high-current flexible busbar, wherein the copper wire busbar 1 serves as a basic conductive unit, its function being to achieve efficient current conduction and provide a mechanical support foundation.

[0023] Each copper wire busbar 1 includes several conductive parts 11. Each conductive part 11 is arranged one by one along a straight line. The central axis L1 of each conductive part 11 is parallel to each other in the length extension direction. The peripheral surfaces 111 of each conductive part 11 are connected in sequence to form a contact surface 112. Multiple contact protrusions 12 are uniformly arranged on the contact surface 112, thereby forming a contact groove 13 between every two adjacent contact protrusions 12. Between every two adjacent copper wire bars 1, each contact protrusion 12 on one copper wire bar 1 is inserted into a corresponding contact groove 13 on the other copper wire bar 1, and the contact protrusion 12 abuts against the contact surface 112.

[0024] Understandably, the conductive parts 11 are arranged one by one along a straight line to form a continuous current path, thereby optimizing current distribution and reducing resistance loss. The central axes L1 of each conductive part 11 are parallel to each other in the length extension direction, which can ensure the consistency of current flow and structural stability. The peripheral surfaces 111 of each conductive part 11 are connected in sequence to form a contact surface 112, which can provide a contact interface for adjacent copper wire busbars 1 to promote heat transfer and mechanical fit.

[0025] The contact protrusions 12 are inserted into the contact grooves 13 and abut against the contact surface 112 to form a regular gap space during mating. The contact grooves 13 formed between two adjacent contact protrusions 12 refer to the two adjacent contact protrusions 12 jointly defining a contact groove 13 on the contact surface 112. The contact grooves 13 are used to accommodate the contact protrusions 12 and maintain a uniform distribution of the gap space, thereby synergistically enhancing heat dissipation efficiency.

[0026] It should be noted that, through the cooperation and support of the contact protrusion 12 and the contact groove 13, a regular gap space is formed between adjacent copper wire busbars 1, which significantly increases the effective heat dissipation area of ​​the copper wire busbar cell 10 per unit volume, and at the same time improves the air circulation efficiency between the mating surfaces. This efficiently dissipates the heat generated by the skin effect of current and resistance, thereby significantly improving the heat dissipation performance of the product.

[0027] like Figures 1 to 3 As shown, in some embodiments of the copper wire busbar 10, the width of the contact protrusion 12 is less than or equal to the interval between two adjacent contact protrusions 12.

[0028] Understandably, let the width of the contact protrusion 12 be W1, and the interval between two adjacent contact protrusions 12 be D1. Where W1 ≤ D1. This dimensional relationship ensures that the contact protrusions 12 maintain a uniform distribution of regular gap space when inserted into the contact grooves 13 of adjacent copper wire busbars 1. Furthermore, when W1 ≤ D1, after adjacent copper wire busbars 1 are stacked, the fit between the contact protrusions 12 and the contact grooves 13 will not cause local compression or blockage of the gap space.

[0029] It should be noted that by constraining the width W1 of the contact protrusion 12 to be less than or equal to the interval D1, the shape and distribution density of the gap space are optimized while maintaining the mechanical stability between adjacent copper wire bars 1. This design significantly improves the heat transfer efficiency to the air and enhances the airflow's ability to dissipate heat from the skin effect, thereby achieving a secondary gain in heat dissipation performance within a limited volume, forming a synergistic effect with the contact protrusion-concave mating structure.

[0030] Specifically, in some embodiments of the copper wire busbar cell 10, the spacing between two adjacent contact protrusions 12 on each copper wire busbar 1 is 1mm to 3mm. It should be noted that within this size range, the distribution density of the contact grooves 13 and the contact protrusions 12 can be optimally matched, avoiding gap space blockage due to excessively small spacing or reduced heat dissipation area gain due to excessively large spacing. Specifically, in some embodiments of the copper wire busbar cell 10, the thickness T2 of the copper wire busbar 1 is 1.5mm to 5.5mm. It should be noted that in practical applications, the thickness T2 of the copper wire busbar 1 can be flexibly set according to the actual loss due to the skin effect and the current carrying capacity. Specifically, in some embodiments of the copper wire busbar cell 10, the width W2 of the copper wire busbar 1 is 20mm to 150mm.

[0031] like Figures 1 to 3 As shown, in some embodiments of the copper wire busbar 10, each copper wire busbar 1 has rounded corners at both ends in the length direction.

[0032] Understandably, the rounded corners eliminate the sharp edges at the ends of the copper wire busbar 1, thereby avoiding the risk of insulation layer puncture and suppressing the tip discharge effect under high voltage electric field.

[0033] In some embodiments of the copper wire busbar 10, the cross-section of the copper wire busbar 10 is rectangular.

[0034] Understandably, the cross-section of the copper wire busbar 10 can also be roughly rectangular. A rectangular or nearly rectangular cross-section can achieve the maximum current transmission per unit area and improve the load capacity of the product.

[0035] Figures 1 to 3The high-current flexible busbar 20 in some embodiments of the present invention is also shown, which includes a copper wire busbar core 10 and an encapsulation assembly 30, the encapsulation assembly 30 being sleeved on the copper wire busbar core 10.

[0036] Understandably, the copper wire busbar 10 serves to conduct current. The encapsulation assembly 30 is fitted over the copper wire busbar 10 to protect it.

[0037] like Figures 1 to 3 As shown, in some embodiments of the high-current flexible busbar 20, the encapsulation assembly 30 includes a wrapping layer 31, an insulation layer 32, and a sheath layer 33; The wrapping layer 31 is wound around the copper wire bus core 10, the insulation layer 32 is sleeved on the wrapping layer 31, and the sheath layer 33 is sleeved on the insulation layer 32.

[0038] Understandably, the wrapping layer 31 fixes the stacked position of the copper wire busbar 1 through the winding tension, maintaining the engagement between the contact protrusion 12 and the contact groove 13. At the same time, the wrapping layer 31 can also disperse the local shear force of the copper wire busbar cell 10 when it is bent. In addition, the wrapping layer 31 can also suppress the fretting wear between the layers of the copper wire busbar 1, extending the cell life.

[0039] The insulating layer 32 is used to block the electrical connection between the copper wire bus core 10 and the external environment. The sheath layer 33, as the outermost layer, serves to protect all the inner layers.

[0040] Specifically, the wrapping layer 31 includes a wrapping tape, which is tightly wrapped around the copper wire bus 10 to form the wrapping layer 31.

[0041] It should be noted that the specific wrapping method of the packaging strap can be flexibly set and adjusted according to the design and usage requirements of the tea.

[0042] Specifically, the insulation layer includes a polyvinyl chloride layer or a cross-linked polyethylene layer.

[0043] Understandably, the polyvinyl chloride layer can be tightly wrapped around the wrapping layer 31 through an extrusion process, reducing production costs and adapting to high-speed continuous manufacturing. Using a cross-linked polyethylene layer to make the insulation layer can improve temperature resistance and breakdown strength.

[0044] Specifically, the sheath layer includes a silicone rubber sheath or a polyolefin sheath.

[0045] Understandably, using a silicone rubber sheath as the sheath layer can expand the product's temperature range and improve its flame retardancy rating. Combined with the high heat dissipation design of the copper wire busbar 10, it can resist the risk of thermal runaway.

[0046] Using a polyolefin sheath as the sheath layer can improve the product's resistance to corrosive environments.

[0047] The following are the beneficial effects of implementing this utility model: This utility model relates to a copper wire busbar battery core and a high-current flexible busbar, wherein the high-current flexible busbar is provided with a copper wire busbar battery core. On the copper wire busbar battery core, by setting a structure in which several copper wire busbars are stacked one by one, and by setting the contact protrusions and contact grooves on each copper wire busbar in a matching insertion manner (that is, between adjacent copper wire busbars, the contact protrusions of one copper wire busbar are inserted into the contact grooves of another copper wire busbar, and the contact protrusions abut against the contact surface), a regularly distributed gap space is formed between adjacent copper wire busbars.

[0048] This significantly increases the effective heat dissipation area of ​​the copper wire busbar per unit volume, while also improving the airflow efficiency between the mating surfaces. This efficiently dissipates the heat generated by the skin effect and resistance, thereby significantly improving the product's heat dissipation performance.

[0049] The present invention has been described in detail above with reference to the accompanying drawings. In the above embodiments, the descriptions of each embodiment have different focuses; for parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments. Those skilled in the art should also understand that the actions and modules involved in the specification are not necessarily essential to the present invention. Furthermore, it is understood that the steps in the method of the present invention embodiments can be adjusted, combined, and deleted according to actual needs, and the modules in the device of the present invention embodiments can be combined, divided, and deleted according to actual needs.

[0050] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A copper wire busbar battery core, characterized in that, It includes several copper wire bars, and each copper wire bar is stacked one on top of the other; Each of the copper wire bars includes several conductive parts, each conductive part is arranged one by one along a straight line, and the central axes of each conductive part are parallel to each other in the length extension direction. The peripheral surfaces of each conductive part are connected in sequence to form a contact surface. Multiple contact protrusions are uniformly arranged on the contact surface, thereby forming a contact groove between every two adjacent contact protrusions. Between every two adjacent copper wire rows, each contact protrusion on one of the copper wire rows is inserted into a corresponding contact groove on the other copper wire row, and the contact protrusion abuts against the contact surface.

2. The copper wire busbar cell according to claim 1, characterized in that, The width of the contact protrusion is less than or equal to the interval between two adjacent contact protrusions.

3. The copper wire busbar cell according to claim 1 or 2, characterized in that, On each of the copper wire bars, the spacing between two adjacent contact protrusions is 1mm to 3mm; and / or The thickness of the copper wire busbar is 1.5mm to 5.5mm; and / or The width of the copper wire busbar is 20mm to 150mm.

4. The copper wire busbar cell according to claim 1, characterized in that, Each of the copper wires has rounded corners at both ends along its length.

5. The copper wire busbar cell according to claim 1, characterized in that, The cross-section of the copper wire busbar is rectangular.

6. A high-current flexible busbar, characterized in that, The high-current flexible busbar includes the copper wire busbar as described in any one of claims 1 to 5, and further includes an encapsulation assembly, which is sleeved on the outside of the copper wire busbar.

7. The high-current flexible busbar according to claim 6, characterized in that, The encapsulation assembly includes a wrapping layer, an insulating layer, and a sheath layer; The wrapping layer is wound around the outside of the copper wire bus core, the insulating layer is sleeved on the outside of the wrapping layer, and the sheath layer is sleeved on the outside of the insulating layer.

8. The high-current flexible busbar according to claim 7, characterized in that, The wrapping layer includes a wrapping tape, which is tightly wrapped around the outside of the copper wire busbar to form the wrapping layer.

9. The high-current flexible busbar according to claim 7, characterized in that, The insulating layer includes a polyvinyl chloride layer or a cross-linked polyethylene layer.

10. The high-current flexible busbar according to claim 7, characterized in that, The sheath layer includes a silicone rubber sheath or a polyolefin sheath.

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