A two-shot overmolded laminated busbar assembly

Abstract

The utility model discloses a kind of secondary injection molding laminated busbar assembly, including busbar assembly and insulating limiting piece, busbar assembly includes the busbar body of up-down stack arrangement;Insulating limiting piece includes the inner insulating piece and outer insulating piece successively formed between adjacent busbar body and outside busbar assembly, the double positioning structure of the limiting post and limiting groove of inner insulating piece in the utility model, realize the accurate fixing of busbar body, avoid displacement in injection molding process;The contour groove of outer insulating piece and support boss further snap busbar assembly, double limiting makes laminated busbar far superior to the limiting precision of traditional disposable injection molding;Adopt secondary injection molding process of first inside then outside, completely solve the bubble problem between adjacent busbar in traditional disposable injection molding, insulation layer withstand voltage performance significantly improves, with higher practical value.

Description

Technical Field

[0001] This utility model relates to the field of stacked busbar assembly technology, specifically to a secondary injection molded stacked busbar assembly. Background Technology

[0002] As a composite electrical connection device formed by alternating layers of conductive plates and insulating materials, the laminated busbar is injection molded with conductive materials such as copper and aluminum and insulating components in one piece. Compared with traditional copper busbars, it has significant advantages such as reducing stray inductance by more than 40% and reducing cabinet size by 30%. At the same time, its modular assembly characteristics make it widely used in new energy vehicles, energy storage systems, industrial frequency converters and other scenarios with high requirements for compact electrical connections and low inductance.

[0003] The insulation fixing of existing laminated busbars mostly adopts a one-time injection molding process. This method has the following core technical defects, affecting product processing quality and reliability: One-time injection molding requires multiple sets of limiting holes to be opened on the busbar body. Fixing is achieved by inserting the injection molded part into the limiting holes. However, the busbar is prone to displacement due to the impact of molten material during injection molding, resulting in deviations in lamination accuracy and affecting the accuracy of electrical connections. During one-time injection molding, the gap between adjacent busbar bodies is narrow, and the molten insulation material fills quickly, easily trapping air and forming bubbles. These bubbles reduce the withstand voltage performance and structural strength of the insulation layer, and may lead to insulation breakdown risk with long-term use. The insulation parts formed by one-time injection molding cannot meet the dual requirements of busbar limiting and overall fixing. The busbar assembly is prone to shaking during subsequent assembly, and the arrangement stability of the connection terminals is poor. Utility Model Content

[0004] In view of the deficiencies in the existing technology, the purpose of this utility model is to provide a secondary injection molding laminated busbar assembly, which can effectively solve the problems of unstable positioning, residual air bubbles, and insufficient insulation safety in the existing one-time injection molding process.

[0005] The technical solution adopted by this utility model is: a secondary injection molded laminated busbar assembly, including a busbar assembly and an insulating limiting member. The busbar assembly includes a busbar body arranged in a stacked manner. The insulating limiting member includes an inner insulating member and an outer insulating member formed sequentially between adjacent busbar bodies and outside the busbar assembly. The upper and lower surfaces of the inner insulating member are provided with limiting posts, which pass through limiting holes provided on the busbar body. The outer insulating member has an assembly space for installing the busbar assembly, and the outer surface of the outer insulating member has a receiving groove for accommodating the connection terminals of the busbar body.

[0006] In this technical solution, the problem of limiting and fixing adjacent busbar bodies is solved by forming an inner insulating component between the stacked busbar bodies. The busbar bodies can be limited by the cooperation of limiting posts and limiting holes to ensure the stability of the busbar assembly. The busbar assembly assembled by limiting the inner insulating component can be assembled inside the outer insulating component, and the receiving groove can stably arrange the connecting terminals on the surface of the outer insulating component. Since the inner and outer insulating components are formed sequentially, the limiting assembly and insulation assembly of the busbar bodies are achieved sequentially. Compared with the traditional method of using a one-time molded insulating limiting component, this solves the problem of limiting the busbar bodies and the problem of air bubbles between adjacent busbar bodies during the forming process, thus improving the processing quality of the stacked busbars.

[0007] Preferably, the upper and lower surfaces of the inner insulating component are provided with limiting grooves adapted to the contour of the busbar body, and the limiting post is disposed in the limiting groove.

[0008] Preferably, the abutment is abutted where the edge of the inner insulating member contacts the inner side of the connection terminal of the busbar body.

[0009] Preferably, the inner and outer insulating components are formed using injection molding.

[0010] Preferably, the outer surface of the outer insulating component has isolation protrusions between adjacent receiving grooves.

[0011] Preferably, the assembly space of the outer insulating component and the inner wall opposite to the upper and lower busbar bodies are respectively formed with contour grooves and spaced support bosses.

[0012] Preferably, the inner wall of the assembly space of the outer insulation component has a supporting boss on one side, and a supporting component for the busbar assembly is also provided.

[0013] The beneficial effects of this utility model are as follows: In this utility model, the busbar body is precisely fixed through the dual positioning structure of the limiting post and limiting groove of the inner insulating component, avoiding displacement during injection molding; the contour groove and supporting boss of the outer insulating component further engage the busbar assembly, and the dual limiting makes the stacked busbar far superior to the limiting accuracy of traditional one-time injection molding; adopting the two-stage injection molding process of inside first and then outside, the inner insulating component is only filled in the gap between adjacent busbars during injection molding, the space is open and the filling speed is controllable, avoiding air entrainment; the outer insulating component relies on the fixation of the inner insulating component during injection molding, the filling path is smooth, completely solving the problem of air bubbles between adjacent busbars in traditional one-time injection molding, and the pressure resistance performance of the insulation layer is significantly improved, which has high practical value. Attached Figure Description

[0014] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0015] Figure 1 This is an assembly perspective view of the secondary injection molded laminated busbar assembly provided in the embodiments of this utility model.

[0016] Figure 2 This is a schematic diagram of the assembly of the busbar body of the secondary injection molded laminated busbar assembly provided in this embodiment of the present utility model.

[0017] Figure 3 This is a perspective view of the external insulation component of the secondary injection molded laminated busbar assembly provided in the embodiments of this utility model.

[0018] Reference numerals in the attached drawings: busbar body 100, connecting terminal 110, inner insulation component 200, limiting post 210, limiting groove 220, abutment platform 230, outer insulation component 300, assembly space 310, receiving groove 320, isolation protrusion 330, and support protrusion 340. Detailed Implementation

[0019] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0020] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application shall have the ordinary meaning as understood by one of ordinary skill in the art to which this utility model pertains.

[0021] like Figures 1 to 3 As shown, a specific embodiment of this utility model provides a secondary injection molded laminated busbar assembly, which has significantly improved processing quality compared to traditional laminated busbars; it includes a busbar assembly and an insulating limiting component, wherein the busbar assembly includes a busbar body 100 stacked vertically; the insulating limiting component includes an inner insulating component 200 and an outer insulating component 300 formed sequentially between adjacent busbar bodies 100 and outside the busbar assembly.

[0022] like Figures 1 to 3As shown, the inner insulating component 200 and the outer insulating component 300 are successively injection molded. During the injection molding process, the inner insulating component 200 has limiting posts 210 on its upper and lower surfaces, which pass through limiting holes provided on the busbar body 100. At the same time, the inner insulating component 200 has limiting grooves 220 on its upper and lower surfaces that are adapted to the contour of the busbar body 100, and the limiting posts 210 are located in the limiting grooves 220. In this way, the busbar body 100 can be fixed in the formed limiting grooves 220, and the limiting posts 210 and the limiting holes cooperate to improve the limiting firmness of the busbar body 100. After the busbar body 100 of the stacked busbar is fixed by the inner limiting component, it still needs to be assembled. In this embodiment, the outer insulating component 300 has an assembly space 310 for installing busbar components, and the outer surface of the outer insulating component 300 has a receiving groove 320 for accommodating the connection terminals 110 of the busbar body 100. This ensures that the busbar assembly remains stable after assembly, and the connection terminals 110 can be stably arranged on the surface of the outer insulation component 300 for connecting the circuit. Since the inner insulation component 200 and the outer insulation component 300 are formed sequentially, the limiting assembly and insulation assembly of the busbar body 100 are realized sequentially. During the injection molding process, the assembly space 310 of the outer insulation component 300 and the inner wall opposite to the upper and lower busbar bodies 100 are respectively formed with contour grooves and spaced support protrusions 340. The support protrusions can support the busbar assembly, so that the busbar body 100 can be inserted into the contour groove, thereby preventing the busbar assembly from shaking in the assembly space 310 and improving the stability of the assembly.

[0023] Compared with the traditional method of assembling with one-time molded insulating limiting parts, this method solves the limiting problem of the busbar body 100 and the problem of air bubbles between adjacent busbar bodies 100 during the molding process, thus improving the processing quality of the laminated busbar.

[0024] like Figure 2 As shown, the connection terminals 110 of the busbar body 100 need to be connected to the circuit. In this embodiment, an abutment 230 is provided at the edge of the inner insulating member 200, which contacts the inner side of the connection terminals 110 of the busbar body 100. The abutment 230 can improve the stability of the connection terminals 110. At the same time, in order to improve the insulation safety of the connection of the connection terminals 110, this embodiment also provides an isolation protrusion 330 between adjacent receiving grooves 320 on the outer surface of the outer insulating member 300. The isolation protrusion 330 can isolate adjacent connection terminals 110, thereby making the connection safer. In addition, a support member for supporting the busbar assembly is provided on the side of the inner wall of the assembly space of the outer insulating member 399 with the support protrusion. The support member is used to fill the gap between the inner wall of the assembly space and the busbar assembly, improving the stability during injection molding assembly.

[0025] In summary, this utility model, through its secondary injection molding design with internal limiting and external encapsulation, completely solves the problems of unstable limiting and residual air bubbles in traditional one-time injection molding, while taking into account processing accuracy, structural stability, and insulation safety.

[0026] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model, and they should all be covered within the scope of the claims and specification of this utility model.

Claims

1. A secondary injection-molded laminated busbar assembly, characterized in that; Including busbar assemblies and insulating limiters, The busbar assembly includes busbar bodies (100) stacked vertically; The insulating limiting component includes an inner insulating component (200) and an outer insulating component (300) formed sequentially between adjacent busbar bodies (100) and outside the busbar assembly. The inner insulating component (200) has limiting posts (210) on its upper and lower surfaces, and the limiting posts (210) pass through limiting holes provided on the busbar body (100). The outer insulating component (300) has an assembly space (310) for installing the busbar assembly, and the outer surface of the outer insulating component (300) has a receiving groove (320) for accommodating the connection terminal (110) of the busbar body (100).

2. The secondary injection-molded laminated busbar assembly according to claim 1, Its characteristics are: The inner insulating component (200) has a limiting groove (220) on its upper and lower surfaces that is adapted to the contour of the busbar body (100), and the limiting post (210) is located in the limiting groove (220).

3. The secondary injection-molded laminated busbar assembly according to claim 1, Its characteristics are: The inner insulating member (200) has an edge that contacts the inner side of the connection terminal (110) of the busbar body (100) and abutment (230).

4. The secondary injection molded laminated busbar assembly according to claim 1, characterized in that... ； The inner insulating component (200) and the outer insulating component (300) are formed by injection molding.

5. The secondary injection-molded laminated busbar assembly according to claim 1, Its characteristics are: The outer surface of the outer insulating component (300) is provided with an isolation protrusion (330) between adjacent receiving grooves (320).

6. The secondary injection-molded laminated busbar assembly according to claim 1, Its characteristics are: The assembly space (310) of the outer insulating component (300) and the inner wall opposite to the upper and lower busbar bodies (100) are respectively formed with contour grooves and spaced support bosses (340).

7. The secondary injection-molded laminated busbar assembly according to claim 6, Its characteristics are: The inner wall of the assembly space (310) of the outer insulation component (300) has a supporting boss (340) on one side, and a supporting component for the busbar assembly is also provided.

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