Multilayer composite structure of a hard copper busbar cable arrangement

Abstract

Multilayer composite structure of a hard copper busbar cable arrangement, characterized in that it comprises a first insulating layer, a first conductive layer, a second insulating layer, a second conductive layer, a third insulating layer, a third conductive layer, a fourth insulating layer, a fourth conductive layer, and a fifth insulating layer, which are arranged stacked from top to bottom, wherein an adhesive layer is further provided between the adjacent insulating and conductive layers, which serves to connect and fix these two; a central positioning hole extending in the thickness direction of the copper busbar cables penetrates the aforementioned stacked insulating, adhesive, and conductive layers and interacts with a positioning pin to achieve positioning during the stacking of the individual layers;Each conductive layer comprises a copper rail and insulating parts arranged on both sides of the copper rail.

Description

Technical field

[0001] The utility model belongs to the technical field of copper busbar cables and relates in particular to a multi-layer composite structure of a hard copper busbar cable arrangement. Background technology

[0002] Cable assemblies are used in fields such as communications, new energy, and industry, and must enable electrical connections between electronic device systems. Conventional cable assemblies have a bulky structure, complex wiring methods, and are time-consuming to install, significantly increasing the difficulty and cost of on-site cabling. Hard copper busbar cable assemblies are characterized by high structural integration and ease of handling. They enable rapid on-site cabling in confined spaces, saving installation space and offering quick and easy wiring. They are frequently used in highly integrated applications such as 5G base stations and new energy storage systems.

[0003] Currently, ensuring press-fit accuracy during crimping is difficult with hard copper rail assemblies. Furthermore, precise positioning at numerous conductive points is challenging, impacting assembly efficiency and reducing productivity.

[0004] Furthermore, in existing copper rail arrangements, the conductive parts of the conductive layers are exposed, which poses a safety risk. Content of the invention

[0005] To solve the aforementioned problems, the utility model provides a novel structure of a multi-layered composite structure of a hard copper busbar cable arrangement, which enables mounting positioning and insulation protection.

[0006] The purpose of the utility model and the solution to its technical problem are achieved by the following technical measures. According to the proposed utility model, a multilayer composite structure of a hard copper busbar cable assembly is provided, comprising a first insulating layer, a first conductive layer, a second insulating layer, a second conductive layer, a third insulating layer, a third conductive layer, a fourth insulating layer, a fourth conductive layer, and a fifth insulating layer, arranged stacked from top to bottom, with an adhesive layer further provided between the adjacent insulating and conductive layers for the purpose of joining and fixing these two;A central positioning hole extending in the thickness direction of the copper busbar cable penetrates the aforementioned stacked insulating, adhesive, and conductive layers and interacts with a positioning pin to ensure pressing accuracy during the hot pressing of the multilayered copper busbar cable. Each conductive layer comprises a copper busbar and insulating elements arranged on both sides of the copper busbar to provide insulation protection for the conductive layer.

[0007] The purpose of the utility model and the solution to its technical problem can be further achieved through the following technical measures.

[0008] The aforementioned multilayer composite structure of a hard copper busbar cable arrangement, in which one of the above-mentioned conductive layers has two copper busbars and an insulating part is arranged between the two copper busbars; the other conductive layers have only one copper busbar.The aforementioned multilayer composite structure of a hard copper busbar cable arrangement, wherein, when the conductive layer has two copper busbars, the central positioning hole passes through the insulating part between the two copper busbars and the diameter of this central positioning hole is larger than the space between the two copper busbars, the two copper busbars being bent away from each other at the central positioning hole; when the conductive layer has only one copper busbar, the central positioning hole passes through this copper busbar and an annular insulating part is further arranged between the central positioning hole and the copper busbar.

[0009] The aforementioned multi-layered composite structure of a hard copper busbar cable arrangement, in which the copper busbar and the insulating parts of the same conductive layer maintain a constant width at different positions in the direction of extension.

[0010] The aforementioned multi-layered composite structure of a hard copper busbar cable arrangement, in which the insulating parts in the conductive layers and the insulating layers are FR-4 epoxy resin sheets; the adhesive layer is a PP prepreg.

[0011] The aforementioned multi-layered composite structure of a hard copper busbar cable arrangement, in which the entire outer surface of this cable arrangement is sprayed with a conductive metallic paint, wherein an elastic conductive piece is attached to the surface of this conductive metallic paint, which serves for contacting and conductive connection with an adaptable shielding structure.

[0012] The aforementioned multi-layered composite structure of a hard copper busbar cable arrangement, in which the surface of the parts of the copper busbars in the conductive layers that protrude from the insulating parts is not sprayed with the conductive metal lacquer.

[0013] The aforementioned multi-layered composite structure of a hard copper busbar cable assembly, in which both ends of each copper busbar are provided with a terminal lug that protrudes for connection and conductive contact with a connecting element to be adapted, wherein, in the assembly of this cable assembly, the insulating layer located below has a projection extending beyond the other insulating layers, which is suitable to fill the gap between the terminal lug and the mounting plate in order to prevent the terminal lug fixing screw from falling through the recessed hole in the mounting plate.

[0014] The aforementioned multilayer composite structure of a hard copper busbar cable arrangement is characterized by the fact that the surface of the extension is not sprayed with the conductive metal lacquer.

[0015] The aforementioned multi-layered composite structure of a hard copper busbar cable assembly, in which at least one extension is provided with at least one positioning section that interacts with a positioning structure on the mounting plate to enable rapid positioning during assembly of this cable assembly, exhibits clear advantages and positive effects compared to the prior art. Through the aforementioned technical scheme, the utility model can achieve significant technological advancement and practicality and possesses broad industrial application value. It has at least the following advantages: The utility model relates to a multi-layered composite structure of a hard copper busbar cable assembly. Adding a mounting positioning structure to the copper busbar improves the pressing accuracy during the hot pressing of the multi-layered FR-4 epoxy resin boards, PP prepregs, and copper busbars. With numerous mounting points, positioning the copper busbar assembly can be challenging. The utility model, by adding a positioning structure to the copper busbar, enables quick and accurate positioning, effectively reducing the difficulty of on-site assembly and significantly improving assembly efficiency. Fastening screws for copper busbar accessories tend to fall out during assembly and into the housing interior.To avoid this problem, the FR-4 epoxy resin plates are extended around the screw mounting holes to fill the gap, effectively reducing the risk of screws falling out and being lost. Simultaneously, to combat electromagnetic interference, the surface of the FR-4 epoxy resin plate of this copper busbar cable is sprayed with a conductive metallic paint. Combined with the elastic conductive piece, this significantly improves the shielding performance of the copper busbar.

[0016] The utility model realizes the switching function of multiple circuits through the multi-layered composite structure of the copper busbar and innovatively arranges two circuits on the same layer, thereby further increasing the integration level of the copper busbar circuit. Figures Fig. Figure 1 is a cross-sectional view of the multi-layered composite structure of the hard copper busbar cable arrangement according to the utility model; Fig. Figure 2 is a top view after removal of the first layer of the FR-4 epoxy resin board according to the utility model; Fig. Figure 3 is a top view after removal of the second layer of the FR-4 epoxy resin board and the parts above it, in accordance with the utility model; Fig. Figure 4 is a top view after the removal of the third layer of the FR-4 epoxy resin board and the parts above it, in accordance with the utility model; Fig. Figure 5 is a top view after the removal of the fourth layer of the FR-4 epoxy resin board and the parts above it, in accordance with the utility model; Fig. Figure 6 is a top view of the multilayer composite structure of the hard copper rail cable arrangement according to the utility model; Fig. Figure 7 is a schematic composition view of the multilayer composite structure of the hard copper rail cable arrangement according to the utility model; Fig. Figure 8 is a schematic assembly view of the multilayer composite structure of the hard copper busbar cable arrangement according to the utility model; Fig. Figure 9 is a top view of the assembly state of the multilayer composite structure of the hard copper busbar cable arrangement according to the utility model; Fig. Figure 10 is a schematic view of the copper busbar shielding structure of the multilayer composite structure of the hard copper busbar cable arrangement according to the utility model. Specific embodiments

[0017] In order to further explain the technical means and effects employed by the utility model to achieve the intended purpose of the invention, the specific implementation form, structure, features and effects of the proposed multilayer composite structure of a hard copper busbar cable arrangement are described in detail below with reference to the accompanying drawings and preferred embodiments.

[0018] Please note the Fig.Figures 1-10 are schematic views of the individual structural components of the multilayer composite structure of the hard copper busbar cable assembly according to the utility model. This copper busbar cable assembly comprises a first insulating layer 1, a first conductive layer 2, a second insulating layer 3, a second conductive layer 4, a third insulating layer 5, a third conductive layer 6, a fourth insulating layer 7, a fourth conductive layer 8, and a fifth insulating layer 9, arranged sequentially from top to bottom. An adhesive layer 10 is also provided between adjacent layers of the aforementioned copper busbar cable assembly; that is, an adhesive layer 10 is also provided between adjacent insulating and conductive layers. This adhesive layer 10 serves to create the connection and fix the adjacent insulating and conductive layers.In this embodiment, the adhesive layer 10 is a PP prepreg, but is not limited to this. The insulating layer is an FR-4 epoxy resin board.

[0019] The utility model is provided with a central positioning hole 13 along the thickness direction of the copper busbar cable, which penetrates the copper busbar cable. This central positioning hole penetrates each insulating layer, adhesive layer, and conductive layer in the thickness direction. This allows the stacked insulating layers, adhesive layers, and conductive layers to be connected to each other by a positioning pin 14, which is adapted to this central positioning hole 13, when the individual layers of this copper busbar cable are stacked.This enables rapid positioning of the stacked insulating and conductive layers during stacking and can prevent the aforementioned insulating, adhesive, and conductive layers from shifting under external force after stacking has been completed, thus ensuring the pressing accuracy and quality of the product formed by stacking during hot pressing.

[0020] In the embodiment of the utility model, one of the layers of the first conductive layer 2, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 has two copper busbars 11, with an insulating element arranged between the two copper busbars; the other layers of the aforementioned conductive layers each comprise one copper busbar 11. The central positioning hole penetrates the copper busbars 11 of each conductive layer. That is, if the conductive layer has only one copper busbar, the central positioning hole 13 penetrates this copper busbar 11; if the conductive layer has two copper busbars 11, the central positioning hole is located between the two copper busbars and penetrates the insulating element between the two copper busbars.

[0021] In the exemplary embodiment of the utility model, the first conductive layer 2 comprises two parallel copper busbars 11. The two copper busbars 11 can provide a connection between the two endpoints of two current paths, thereby increasing the circuit transfer capability and improving the integration level of the copper busbar cable without increasing the number of layers in the copper busbar cable arrangement. An insulating element, an FR-4 epoxy resin plate 12, is provided between the two copper busbars 11 to achieve insulating separation. Since the inner diameter of the central positioning hole 13 is larger than the distance between the two copper busbars 11, the copper busbars 11 are bent outwards at this point to bypass the central positioning hole 13, forming a bent section.The bending directions of the bending sections of the two copper rails 11 are opposite; both are circular arcs, the convex side of the arc points away from the central positioning hole 13, and the FR-4 epoxy resin plate 12 is located between the central positioning hole 13 and the two copper rails 11. In this embodiment, the width of the bending section of the copper rail is consistent with the width of other parts in its extension direction, so that the width of the copper rail remains constant in its extension direction and the conductivity is uniform at all points. Preferably, the width of the FR-4 epoxy resin plate 12 around the central positioning hole 13 is consistent with the width of the FR-4 epoxy resin plate 12 at positions without a central positioning hole 13.

[0022] In the exemplary embodiment of the utility model, insulating elements are provided on the side of each of the two copper busbars 11 of the first conductive layer 2 that faces away from the other copper busbar, in order to provide insulation protection. Preferably, these insulating elements are FR-4 epoxy resin sheets 12, whereby the copper busbar of this conductive layer is completely covered and protected by the FR-4 epoxy resin sheet 12. In this exemplary embodiment, the width of the FR-4 epoxy resin sheet 12 on the side of the copper busbar facing away from the other copper busbar remains constant in the direction of extension of the copper busbar 11, and its shape is consistent with the shape of the outer surface of the copper busbar on that side.

[0023] The second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 of the utility model each comprise a copper busbar and insulating elements arranged on both sides of this copper busbar. In this embodiment, these insulating elements are FR-4 epoxy resin sheets; that is, the aforementioned conductive layers all have a structure in which two FR-4 epoxy resin sheets clamp a copper busbar. The aforementioned central positioning hole 13 penetrates the copper busbars in the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 to enable direct positioning of the copper busbars. Furthermore, an annular insulating layer, supported by the FR-4 epoxy resin sheet, is arranged between this central positioning hole 13 and the copper busbars of the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8.To achieve its conductivity, the aforementioned copper busbar with the central positioning hole 13 curves outwards at the location of the central positioning hole 13, forming an arc-shaped deflection section. This ensures that its transmission performance remains unchanged, provided the central positioning hole 13 is present. Preferably, the arc-shaped deflection sections projecting to both sides of the copper busbar with the central positioning hole 13 are symmetrical, and the sum of the widths of the two arc-shaped deflection sections is consistent with the width of the copper busbar at the location without the central positioning hole. Furthermore, the width of the FR-4 epoxy resin plates on both sides of this copper busbar remains constant in the direction of extension of the copper busbar, and their shape is consistent with the shape of the side surface of the copper busbar.

[0024] In the embodiment of the utility model, the two copper busbars of the first conductive layer 2 each form a current path 1 and a current path 2 for transmitting electrical signals. At both ends of current path 1 and current path 2, connecting lugs 18 are formed to facilitate a conductive connection with the connecting element to be adapted. At each end of the copper busbar of the second conductive layer 4, two grounding lugs 19 are formed to implement the grounding function of this copper layer. The copper busbar of the third conductive layer 6 forms a current path 3 for transmitting electrical signals. At each end of this current path 3, a connecting lug 18 is formed for connection with the connecting element to be adapted.At each of the two ends of the copper busbar of the fourth conductive layer 8, a grounding lug 19 is formed to implement the grounding function of this copper layer. The utility model implements the switching function of 5 current paths through the four-layer copper busbar structure and arranges two current paths in the first conductive layer, thereby further improving the integration level of the copper busbar.

[0025] To achieve fast and precise positioning of this copper busbar cable on the mounting plate 16, the copper busbar cable of the utility model is not only brought together and positioned by the positioning pin located in the central positioning hole with the corresponding positioning hole on the mounting plate 16, but the insulating layer of this copper busbar cable that is at its lowest point during assembly also has at least one extension 91 that projects beyond other layers, wherein at least one extension 91 is provided with a positioning section that interacts with a positioning structure on the mounting plate 16 to achieve positioning by means of a tongue-and-groove structure. The insulating layer at its lowest point during assembly of this copper busbar cable is either the first or the fifth insulating layer.In this embodiment, the fifth insulating layer is located at the bottom and has a projection 91 on it. The positioning structure on the mounting plate 16 is a positioning pin. The positioning section arranged on the projection 91 is a positioning hole 911 or a positioning groove 912, which interacts with the positioning pin. The positioning hole can be a through hole on the projection 91, the direction of which is aligned with the thickness direction of the copper busbar cable. The positioning groove 912 can be an arcuate groove on one side of the projection, oriented towards the positioning pin.

[0026] In the exemplary embodiment of the utility model, two extensions 91 with different directions of extension are arranged on each side of the fifth insulating layer 9 in the direction of extension, one of the two extensions 91 being provided with a positioning hole 911 on one side and the other with a positioning groove 912. Preferably, the projection centers of the positioning hole 911, the positioning groove 912, and the central positioning hole 13 on the mounting plate are not aligned. During the mounting of the copper busbar cable according to the utility model, three positioning pins on the mounting plate penetrate the three positioning points (positioning hole 911, positioning groove 912, and central positioning hole 13).The copper busbar cable is precisely positioned on the mounting plate, enabling fast and accurate positioning during assembly, saving assembly time and significantly improving assembly efficiency. The utility model features a three-point positioning mounting structure that ensures fast and accurate positioning of the copper busbar cable on the mounting plate at a variety of mounting points.

[0027] The mounting plate 16 is provided with recessed holes 161 at the locations corresponding to the copper busbar connection lugs to facilitate the connection and fixing of the connection lug to the connecting section to be adapted by means of a fastening screw 20. However, when the connection and fixing of the connection lug to the connecting section to be adapted is carried out, the fastening screw 20 tends to fall through the gap between the edge of the connection lug and the recessed hole 161 of the mounting plate 16 and into the interior of the housing, making removal difficult. To prevent the fastening screw 20 from falling out, the extensions 91 of the fifth insulating layer of the utility model are distributed below the connection lugs of the individual copper busbars. They can fill the gap between the copper busbar connection lug and the mounting plate.The extensions 91 have through holes 913 at the locations corresponding to the copper busbar connection lugs. These holes correspond to the fixing part connected to the connection lug, in order to facilitate the connection and fixing of this connection lug to the connecting section to be adapted. Both the gap between the extension 91 and the copper busbar connection lug and the gap between the extension 91 and the mounting plate 16 are smaller than the minimum possible gap through which the fastening screw 20 could fall, thus preventing the fastening screw 20 from falling into the housing.

[0028] The utility model extends the bottom FR-4 plate to implement a screw locking function to prevent it from falling out.

[0029] The outer surface of the copper busbar cable according to the utility model is further coated with a conductive metallic lacquer. This conductive metallic lacquer ensures that all points on the surface of this copper busbar cable are conductively connected; that is, this copper busbar cable is surrounded by a completely closed conductive shield and exhibits good shielding properties. An elastic conductive piece 15 is also attached to the surface of this conductive metallic lacquer. This shielding conductive piece 15 serves to provide overall shielding and grounding of this copper busbar cable in order to prevent electromagnetic interference. In one embodiment, the elastic conductive piece 15 is glued to the lacquered surface of the top layer of this copper busbar cable in order to make contact with and conductively connect a suitable shielding cover, thereby achieving the shielding function.In other embodiments of the utility model, the elastic conductive piece 15 can be arranged in other positions on the painted surface of the copper busbar cable, provided that it can come into contact with the shielding structure to be adapted and connect conductively.

[0030] In this embodiment, when the surface of the copper busbar cable is sprayed with the conductive lacquer, the surface of the copper busbar itself is not sprayed. That is, the surface of the parts of the copper busbars of the individual conductive layers that protrude from the FR-4 epoxy resin plates is not sprayed with the conductive lacquer, and neither is the extension 91 of the lowest insulating layer of this copper busbar cable.

[0031] In particular, the surfaces of the individual insulating and conductive layers of this copper busbar cable that are not in contact with the adjacent layer are all sprayed with the conductive lacquer. Since the copper busbars 11 are surrounded by the FR-4 epoxy resin sheets and the adjacent insulating layers, there is no conductive lacquer on the surface of the copper busbars 11. The utility model combines the conductive metallic lacquer with the elastic conductive element to achieve electromagnetic shielding of the copper busbar and improve its interference immunity.

[0032] The multi-layered composite hard copper busbar structure of the utility model can effectively switch multiple current paths in a confined space; improve the pressing quality of the copper busbar; save assembly time and increase assembly efficiency; and the structure can prevent the screw from falling out, thus avoiding the screw falling into the housing during assembly; the electromagnetic shielding structure of the copper busbar effectively improves the interference immunity of the copper busbar.

[0033] The foregoing are merely preferred embodiments of the utility model and do not constitute a limitation of the utility model in any way. Although the utility model has been disclosed as above with preferred embodiments, these are not intended to limit the utility model. Any person skilled in the art familiar with this field can, without deviating from the scope of protection of the technical solution of the utility model, use the technical content disclosed above to make minor changes or modifications to obtain equivalent embodiments with the same effect. However, any simple change, equivalent modification, or alteration of the above embodiments, based on the technical nature of the utility model and not deviating from the content of the technical solution of the utility model, remains within the scope of protection of the technical solution of the utility model. Reference symbol: 1 First insulating layer 2 First conductive layer 3 Second insulating layer 4 Second conductive layer 5 Third insulating layer 6 Third conductive layer 7 Fourth insulating layer 8 Fourth conductive layer 9 Fifth insulating layer 91 continuation 10 adhesive layers 11 copper rail 12 FR-4 epoxy resin sheets 13 Central positioning hole 14 Positioning pin 15 Elastic conductive piece 16 Mounting plate 17 Area with conductive paint coating

Claims

[1] Multilayer composite structure of a hard copper busbar cable arrangement, characterized by, comprising a first insulating layer, a first conductive layer, a second insulating layer, a second conductive layer, a third insulating layer, a third conductive layer, a fourth insulating layer, a fourth conductive layer, and a fifth insulating layer, arranged stacked from top to bottom, wherein an adhesive layer is further provided between the adjacent insulating and conductive layers for the purpose of joining and fixing these two; a central positioning hole extending in the thickness direction of the copper busbar cables penetrates the aforementioned stacked insulating, adhesive, and conductive layers and interacts with a positioning pin to achieve positioning when stacking the individual layers; each conductive layer comprises a copper busbar and insulating parts arranged on both sides of the copper busbar. [2] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 1, characterized by , that one of the above-mentioned conductive layers has two copper rails and an insulating part is arranged between the two copper rails; the other conductive layers have only one copper rail. [3] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 2, characterized by, that if the conductive layer has two copper rails, the central positioning hole passes through the insulating part between the two copper rails and the diameter of this central positioning hole is larger than the space between the two copper rails, the two copper rails being bent away from each other at the central positioning hole; if the conductive layer has only one copper rail, the central positioning hole passes through this copper rail and a ring-shaped insulating part is further arranged between the central positioning hole and the copper rail. [4] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 3, characterized by that the copper rail and the insulating parts of the same conductive layer maintain a constant width at different positions in the direction of extension. [5] Multilayer composite structure of a hard copper busbar cable arrangement according to one of claims 1-4, characterized by that the insulating parts in the conductive layers as well as the insulating layers are FR-4 epoxy resin sheets; the adhesive layer is a PP prepreg. [6] Multilayer composite structure of a hard copper busbar cable arrangement according to one of claims 1-4, characterized by , that the entire outer surface of this cable assembly is sprayed with a conductive metallic paint, wherein an elastic conductive piece is attached to the surface of this conductive metallic paint for contacting and conductive connection with a shielding structure to be adapted. [7] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 6, characterized by , that the surface of the parts of the copper rails in the conductive layers that protrude from the insulating parts is not sprayed with the conductive metal paint. [8] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 7, characterized by , that both ends of each copper busbar are provided with a terminal lug which protrudes for connection and conductive contact with a connecting element to be adapted, wherein, when mounting this cable assembly, the insulating layer located below has a projection extending beyond the other insulating layers which is suitable to fill the gap between the terminal lug and the mounting plate in order to prevent the terminal lug fixing screw from falling through the recessed hole in the mounting plate. [9] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 8, characterized by that the surface of the extension is not sprayed with the conductive metallic paint. [10] Multilayer composite structure of a hard copper busbar cable arrangement according to claim 8 or 9, characterized by, that at least one extension is provided with a positioning section that interacts with a positioning structure on the mounting plate to enable rapid positioning during the assembly of this cable assembly.

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