Hard copper busbar cable assembly of multi-layer composite structure

Abstract

The utility model relates to a hard copper busbar cable assembly of the multi-layer composite structure, including 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 stacked from top to bottom. There is also an adhesive layer for connecting and fixing one insulating layer to its adjacent conductive layer between them. A central positioning hole extending in a thickness direction of the copper busbar cable penetrates the stacked insulating layers, adhesive layers, and conductive layers, and is matched with a positioning pin to ensure pressing accuracy in hot pressing the multilayer copper busbar cable. Each conductive layer includes a copper busbar and insulating pieces located on two sides of the copper busbar, providing insulation protection. The utility model incorporates a central positioning reference hole structure, which improves positioning accuracy in stacking various layers, effectively improves pressing precision and quality in hot pressing of a product, and enables all conductive copper busbars to remain insulated at the same time.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of copper busbar cables, and particularly relates to a hard copper busbar cable assembly of a multi-layer composite structure.BACKGROUND

[0002] A cable assembly is widely used in the fields of communication, new energy, industry, etc. It is required to establish electrical connection between electronic device systems. A traditional cable assembly, however, has the disadvantages of a heavy structure, a complex wiring way, and time-consuming mounting. This significantly increases difficulty and a cost of on-site cable preparation. A rigid copper busbar cable assembly features high structural integration and a simple structure. This enables rapid cable preparation within a small space, conservation in a mounting space, and simple and rapid cable preparation. Thus, the rigid copper busbar cable assembly can be widely applied to the fields, with a high degree of integration, of 5G base stations, new energy batteries, etc.

[0003] Currently, the rigid copper busbar assembly faces challenges in maintaining the pressing accuracy in pressing. Furthermore, if there are a large number of conductive sites, the rigid copper busbar assembly has the disadvantages of difficulty in mounting positioning, low mounting efficiency, and an adverse effect on working efficiency.

[0004] In addition,as each conductive piece in the conductive layer is exposed, an existing copper busbar assembly presents a potential safety hazard.SUMMARY

[0005] To solve the above problems, the utility model provides a novel hard copper busbar cable assembly of a multi-layer composite structure, provided by assembly positioning and insulation protection.

[0006] An objective of the utility model and solution of the technical problem are implemented by the following technical solution. A hard copper busbar cable assembly of a multilayer composite structure according to the utility model includes 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 stacked from top to bottom. There is also an adhesive layer for connecting and fixing one insulating layer to its adjacent conductive layer between them. A central positioning hole extending in a thickness direction of the copper busbar cable penetrates the stacked insulating layers, adhesive layers, and conductive layers, and is matched with a positioning pin to ensure pressing accuracy in hot pressing the multilayer copper busbar cable. Each conductive layer includes a copper busbar and insulating pieces located on two sides of the copper busbar, providing insulation protection.

[0007] An objective of the utility model and solution of the technical problem may be further implemented by the following technical measures.

[0008] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, two copper busbars are arranged in one of the conductive layers, with an insulating piece arranged therebetween; and the other conductive layers each is provided with only one copper busbar.

[0009] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, if there are two copper busbars in the conductive layer, the central positioning hole penetrates through the insulating piece between the two copper busbars, the central positioning hole has a diameter larger than a gap between the two copper busbars, and the two copper busbars are bent away from each other at the central positioning hole; and if there is only one copper busbar in the conductive layer, the central positioning hole penetrates through the copper busbar and is separated from the copper busbar by an annular insulating piece.

[0010] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, the copper busbar and the insulating piece in one conductive layer maintain a constant width at different positions in an extending direction.

[0011] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, the insulating piece in the conductive layer and the insulating layer are both FR-4 epoxy boards; and the adhesive layer is a PP prepreg.

[0012] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, an entire outer surface of the cable assembly is sprayed with a metallic conductive paint; and an elastic conductive sheet in contact conduction with a mating shielding structure is adhered to a surface of the metallic conductive paint.

[0013] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure,a part of a surface, extending beyond the insulating piece, of the copper busbar in each conductive layer is unsprayed with the metallic conductive paint.

[0014] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, pins in contact conduction with a mating connecting piece protrude from two ends of each copper busbar; in mounting the cable assembly, an extension portion that protrudes beyond the other insulating layers extends from the lowermost insulating layer; and the extension portion is designed to fill a gap between each pin and a mounting board, preventing a connecting screw on each pin from falling through an avoidance hole formed in the mounting board.

[0015] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, a surface of the extension portion is unsprayed with the metallic conductive paint.

[0016] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, at least one extension portion is provided with a positioning portion that is matched with a positioning structure on the mounting board to achieve rapid positioning in mounting the cable assembly. Compared with the prior art, the utility model has significant advantages and beneficial effects. By virtue of the above technical solution, the utility model can achieve considerable technical progress and practicability, has wide industrial use value, and at least has the following advantages:

[0017] The hard copper busbar cable assembly of the multilayer composite structure of the utility model improves the pressing accuracy in multi-layer hot pressing of the FR-4 epoxy board, the PP prepreg, and the copper busbar by adding the positioning structure to the copper busbar. If there are a large number of mounting sites, the copper busbar assembly is difficult in mounting positioning. The utility model adds the positioning structure on the copper busbar, so as to rapidly and accurately position the copper busbar. This significantly reduces the on-site mounting difficulty and greatly improves the mounting efficiency. The screw, as an accessory of the copper busbar, is prone to falling into a chassis in mounting, to avoid which, the FR-4 epoxy board extends around a screw mounting hole to fill a gap, thereby effectively reducing a risk of screw loss after falling. Meanwhile, to resist electromagnetic interference, spraying the surface of the FR-4 epoxy board of the copper busbar cable with the metallic conductive paint, in combination with the elastic conductive sheet, can greatly improve shielding performance of the copper busbar.

[0018] The utility model achieves multi-circuit conduction by means of the copper busbar of the multilayer composite structure, and innovatively provides two paths of copper busbars in one layer, to further increase an integration degree of the circuit of the copper busbars.BRIEF DESCRIPTION OF DRAWINGS

[0019] FIG. 1 is a lateral cross-sectional view of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 2 is a top view of the utility model with a first layer of FR-4 epoxy board removed; FIG. 3 is a top view of the utility model with a second layer of FR-4 epoxy board and a portion above it removed; FIG. 4 is a top view of the utility model with a third layer of FR-4 epoxy board and a portion above it removed; FIG. 5 is a top view of the utility model with a fourth layer of FR-4 epoxy board and a portion above it removed; FIG. 6 is a top view of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 7 is a schematic diagram of a composition of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 8 is a schematic diagram of mounting of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 9 is a top view of a mounting state of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; and FIG. 10 is a schematic diagram of a copper busbar shielding structure of a hard copper busbar cable assembly of a multilayer composite structure of the utility model. [Description of reference numerals of main elements]

[0020] 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: extension portion 10: adhesive layer 11: copper busbar 12: FR-4 epoxy board 13: central positioning hole 14: positioning pin 15: elastic conductive sheet 16: mounting board 17: conductive paint spraying region DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] To further illustrate the technical measures and effects of the utility model for achieving the intended inventive objective, the implementation manners, structures, features and effects of a hard copper busbar cable assembly of a multi-layer composite structure according to the utility model are described below in detail with reference to the accompanying drawings and preferred embodiments.

[0022] Referring to FIGs. 1 - 10, which are schematic structural diagrams of various portions of the hard copper busbar cable assembly of the multi-layer composite structure of the utility model, in which the hard copper busbar cable assembly includes 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, which are sequentially arranged from top to bottom. There is also an adhesive layer 10 between adjacent layers of the copper busbar cable assembly, i.e. between one insulating layer and its adjacent conductive layer. This adhesive layer 10 is used for connecting and fixing the insulating layer to its adjacent conductive layer. In this embodiment, the adhesive layer 10 is a PP prepreg, but it is not limited thereto. The insulating layer is an FR-4 epoxy board.

[0023] For the utility model, a central positioning hole 13 penetrating through the copper busbar cable is provided in a thickness direction of the copper busbar cable. This central positioning hole penetrates through each insulating layer, adhesive layer, and conductive layer in the thickness direction, enabling rapid positioning in stacking the stacked insulating layers and conductive layers by using a positioning pin 14 adapted to the central positioning hole 13 in stacking various layers of the copper busbar cable. This also prevents misalignment of the insulating layers, the adhesive layers, and the conductive layers under an external force after stacking, ensuring pressing accuracy and quality in hot pressing a product formed after stacking.

[0024] In an embodiment of the utility model, two copper busbars 11 are arranged in one of the first conductive layer 2, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8, with an insulating piece arranged therebetween; and the other of the above conductive layers each is provided with one copper busbar 11. The central positioning hole penetrates through the copper busbar 11 of each conductive layer. That is, if there is only one copper busbar in the conductive layer, the central positioning hole 13 penetrates through that copper busbar 11; and if there are two copper busbars 11 in the conductive layer, the central positioning hole 13 is located between the two copper busbars and penetrates through the insulating piece between the two copper busbars.

[0025] In an embodiment of the utility model, the first conductive layer 2 includes two parallel copper busbars 11, which enable conduction between two endpoints of two pathways. Without increasing a number of layers in the copper busbar cable assembly, it can enhance the circuit's transmission capacity and increase an integration degree of the copper busbar cable. The FR-4 epoxy board 12, as an insulating piece for implementing electrical isolation, is arranged between the two copper busbars 11. Since an inside diameter of the central positioning hole 13 is larger than a distance between the two copper busbars 11, the copper busbars 11 here are bent outward to form bending portions for avoiding the central positioning hole 13. The bending portions of the two copper busbars 11 are opposite in bending direction, and are both in an arc shape with its convex portion facing away from the central positioning hole 13. There is still the FR-4 epoxy board 12 between the central positioning hole 13 and the two copper busbars 11. In this embodiment, the bending portion of each copper busbar has a width consistent with those of other portions in its extension direction. This ensures a constant width of the copper busbar in its extension direction, resulting in uniform conductive performance throughout the copper busbar. Preferably, the FR-4 epoxy board 12 around the central positioning hole 13 has a width consistent with that of the FR-4 epoxy board 12 in a portion without the central positioning hole 13.

[0026] In an embodiment of the utility model, insulating pieces for implementing insulation protection are arranged on sides, facing away from each other, of the two copper busbars 11 in the first conductive layer 2. Preferably, the insulating pieces are FR-4 epoxy boards 12. As a result, the copper busbars in this conductive layer are both circumferentially covered and protected by the FR-4 epoxy boards 12. In this embodiment, the FR-4 epoxy board 12 on the side, facing away from the other copper busbar, of the copper busbar 11 remains constant in width in an extension direction of the copper busbar, and remains consistent in shape with that of an outer surface of the copper busbar on its respective side.

[0027] In the utility model, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 each includes one copper busbar and insulating pieces on two sides of the copper busbar. In this embodiment, the insulating pieces are FR-4 epoxy boards, that is, each of the above conductive layers is of a structure with one copper busbar sandwiched between two FR-4 epoxy boards. The above central positioning hole 13 penetrates through the copper busbars in the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8, enabling direct positioning of the copper busbars. There is also an annular insulating layer, supported by the FR-4 epoxy board, between the central positioning hole 13 and the copper busbars in the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8. Furthermore, to meet the requirement for the conductive performance, the copper busbar with the central positioning hole 13 protrudes outward at the central positioning hole 13 to form an arc-shaped avoidance portion. This meets the requirement for arranging the central positioning hole 13 without affecting the copper busbar's transmission performance. Preferably, the arc-shaped avoidance portions protruding from two sides of the copper busbar with the central positioning hole 13 are symmetrical; and a sum of widths of the two arc-shaped avoidance portions is equal to the width of the copper busbar in a portion without the central positioning hole. The FR-4 epoxy boards on the two sides of the copper busbar remain constant in width in the extension direction of the copper busbar, and remain consistent in shape with that of a side surface of the copper busbar.

[0028] In an embodiment of the utility model, the two copper busbars in the first conductive layer 2 form a pathway 1 and a pathway 2 for transmitting electrical signals respectively. Connecting pins 18 are formed at two ends of both the path 1 and the path 2 to facilitate conduction with a mating connecting piece. Two grounding pins 19 are formed at each end of the copper busbar in the second conductive layer 4 to provide a grounding function of the copper busbar in this layer. The copper busbar in the third conductive layer 6 forms a pathway 3 for transmitting an electrical signal. A connecting pin 18 is formed at each end of the pathway 3 for connecting with a mating connecting piece. A grounding pin 19 is formed at each end of the copper busbar in the fourth conductive layer 8 to provide the grounding function of the copper busbar in this layer. The utility model achieves the conduction function of five pathways by means of a four-layer copper busbar structure. In addition, arranging two pathways in the first conductive layer can further increase the integration degree of the copper busbar.

[0029] To rapidly and accurately positioning the copper busbar cable on the mounting board 16, the copper busbar cable of the utility model not only employs a positioning pin penetrating through the central positioning hole to be matched with a corresponding positioning hole formed in the mounting board 16 for positioning, but also is provided with at least one extension portion 91 protruding beyond other layers on the lowermost insulating layer in mounting. The at least one extension portion 91 is provided with a positioning portion that is matched with a positioning structure on the mounting board 16, providing positioning with a concave-convex structure. In mounting, the lowermost insulating layer of the copper busbar cable is either the first insulating layer or the fifth insulating layer. In this embodiment, the fifth insulating layer is arranged at a bottom and is provided with the extension portion 91. The positioning structure on the mounting board 16 is the positioning pin. The positioning portion on the extension portion 91 is either the positioning hole 911 or a positioning groove 912 that is matched with this positioning pin for positioning. The positioning hole may be a through hole formed in the extension portion 91, extending in a direction as the same as the thickness direction of the copper busbar cable. The positioning groove 912 may be an arc-shaped groove, facing the positioning pin, on one side of the extension portion.

[0030] In an embodiment of the utility model, two extension portions 91 in different extension directions are arranged on each side of the fifth insulating layer 9 in its extension direction. On one side, one of the two extension portions 91 is provided with a positioning hole 911, while the other is provided with a positioning groove 912. Preferably, centers of projections of the positioning hole 911, the positioning groove 912, and the central positioning hole 13 onto the mounting board are non-collinear. In mounting the copper busbar cable of the utility model, three positioning pins on the mounting board pass through three positioning points (i.e. the positioning hole 911, the positioning groove 912, and the central positioning hole 13). This ensures accurate positioning of the copper busbar cable on the mounting board, enabling rapid and accurate positioning of the copper busbar with the mounting board in mounting. In this way, it achieves conservation in mounting time and greatly improved mounting efficiency. The utility model incorporates a three-point positioning mounting structure, which achieves rapid and accurate positioning of the copper busbar cable with the mounting board in mounting, even in a case of a large number of mounting points.

[0031] An avoidance hole 161 is formed in the mounting board 16 corresponding to the copper busbar's pin. This allows the pin to be connected and fixed with the mating connecting portion by means of a connecting screw 20. However, in connecting and fixing the pin with the mating connecting portion, the connecting screw 20 is prone to falling into a chassis through a gap between the pin's edge and the avoidance hole 161 of the mounting board 16, making it difficult in retrieval. To prevent the connecting screw 20 from falling, in the utility model, the extension portion 91 of the fifth insulating layer is distributed beneath the pin of each copper busbar, so as to fill the gap between the copper busbar's pin and the mounting board. The extension portion 91, in correspondence to the copper busbar's pin, has a through hole 913 corresponding to a connecting and fixing portion of the copper busbar's pin, in order to connect and fix the pin with the mating connecting portion. Furthermore, a gap between the extension portion 91 and the copper busbar's pin, and a gap between the extension portion 91 and the mounting board 16 are both smaller than a minimum gap through which the connecting screw 20 can fall. This effectively prevents the connecting screw 20 from falling into the chassis.

[0032] In the utility model, the underlying FR-4 board extends to provide an anti-falling function for the screw.

[0033] In the utility model, the outer surface of the copper busbar cable is further sprayed with a metallic conductive paint, which enables conduction throughout the surface of the copper busbar cable, meaning that the copper busbar cable is enclosed by a completely closed conductive shield, providing an excellent shielding effect. An elastic conductive sheet 15 is further fixed to the surface of the metallic conductive paint. The shielding conductive sheet 15 enables shielding grounding of the overall copper busbar cable, thereby preventing electromagnetic interference. In an embodiment, the elastic conductive sheet 15 is adhered to the painted surface of a top layer of the copper busbar cable. The elastic conductive sheet is used for contact conduction with a mating shielding cover board, providing the shielding function. In other embodiments of the utility model, the elastic conductive sheet 15 may be disposed on the painted surface of the copper busbar cable at other positions, provided that it can be in contact conduction with a mating shielding structure.

[0034] In this embodiment, in spraying the conductive paint on the surface of the copper busbar cable, the surface of the copper busbar is not sprayed. That is, the surfaces, extending beyond the FR-4 epoxy board, of two ends of the copper busbar in each conductive layer are unsprayed with the conductive paint, and the extension portion 91 of the underlying insulating layer of the copper busbar cable is also unsprayed with the conductive paint.

[0035] Specifically, surfaces, not in contact to adjacent layers, of all the insulating layers and conductive layers constituting the copper busbar cable are sprayed with the conductive paint. Since the copper busbar 11 is enclosed by the FR-4 epoxy board and the adjacent insulating layer, there is no conductive paint on the surface of the copper busbar 11. The utility model combines the metallic conductive paint with the elastic conductive sheet to provide an electromagnetic shielding function of the copper busbar, thereby enhancing an anti-interference capability.

[0036] The multilayer composite hard copper busbar structure of the utility model enables effective conduction of multiple circuits within a small space, improves the pressing quality of the copper busbar, and saving a mounting time with improved mounting efficiency. Furthermore, the structure can provide screw anti-falling to prevent the screw from falling into the chassis in mounting. The electromagnetic shielding structure of the copper busbar can effectively enhance the anti-interference capability of the copper busbar.

[0037] The above are only preferred embodiments of the utility model and are not intended to limit the utility model in any form. Although the utility model has been disclosed by the preferred embodiments, it is not intended to limit the utility model. Any person familiar with the profession can make some equivalent embodiments changed or modified into equivalent change by using the technical contents disclosed above without departing from the scope of the technical solution of the utility model. However, any simple modification, equivalent change and modification made on the above embodiments according to the technical essence of the utility model without departing from the content of the technical solution of the utility model still belongs to the scope of the technical solution of the utility model.

Examples

Embodiment Construction

[0021]To further illustrate the technical measures and effects of the utility model for achieving the intended inventive objective, the implementation manners, structures, features and effects of a hard copper busbar cable assembly of a multi-layer composite structure according to the utility model are described below in detail with reference to the accompanying drawings and preferred embodiments.

[0022]Referring to FIGs. 1 - 10, which are schematic structural diagrams of various portions of the hard copper busbar cable assembly of the multi-layer composite structure of the utility model, in which the hard copper busbar cable assembly includes 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, which are sequentially arranged from top to bottom. There is also an adhesive layer 10...

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of copper busbar cables, and particularly relates to a hard copper busbar cable assembly of a multi-layer composite structure.BACKGROUND

[0002] A cable assembly is widely used in the fields of communication, new energy, industry, etc. It is required to establish electrical connection between electronic device systems. A traditional cable assembly, however, has the disadvantages of a heavy structure, a complex wiring way, and time-consuming mounting. This significantly increases difficulty and a cost of on-site cable preparation. A rigid copper busbar cable assembly features high structural integration and a simple structure. This enables rapid cable preparation within a small space, conservation in a mounting space, and simple and rapid cable preparation. Thus, the rigid copper busbar cable assembly can be widely applied to the fields, with a high degree of integration, of 5G base stations, new energy batteries, etc.

[0003] Currently, the rigid copper busbar assembly faces challenges in maintaining the pressing accuracy in pressing. Furthermore, if there are a large number of conductive sites, the rigid copper busbar assembly has the disadvantages of difficulty in mounting positioning, low mounting efficiency, and an adverse effect on working efficiency.

[0004] In addition,as each conductive piece in the conductive layer is exposed, an existing copper busbar assembly presents a potential safety hazard.SUMMARY

[0005] To solve the above problems, the utility model provides a novel hard copper busbar cable assembly of a multi-layer composite structure, provided by assembly positioning and insulation protection.

[0006] An objective of the utility model and solution of the technical problem are implemented by the following technical solution. A hard copper busbar cable assembly of a multilayer composite structure according to the utility model includes 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 stacked from top to bottom. There is also an adhesive layer for connecting and fixing one insulating layer to its adjacent conductive layer between them. A central positioning hole extending in a thickness direction of the copper busbar cable penetrates the stacked insulating layers, adhesive layers, and conductive layers, and is matched with a positioning pin to ensure pressing accuracy in hot pressing the multilayer copper busbar cable. Each conductive layer includes a copper busbar and insulating pieces located on two sides of the copper busbar, providing insulation protection.

[0007] An objective of the utility model and solution of the technical problem may be further implemented by the following technical measures.

[0008] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, two copper busbars are arranged in one of the conductive layers, with an insulating piece arranged therebetween; and the other conductive layers each is provided with only one copper busbar.

[0009] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, if there are two copper busbars in the conductive layer, the central positioning hole penetrates through the insulating piece between the two copper busbars, the central positioning hole has a diameter larger than a gap between the two copper busbars, and the two copper busbars are bent away from each other at the central positioning hole; and if there is only one copper busbar in the conductive layer, the central positioning hole penetrates through the copper busbar and is separated from the copper busbar by an annular insulating piece.

[0010] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, the copper busbar and the insulating piece in one conductive layer maintain a constant width at different positions in an extending direction.

[0011] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, the insulating piece in the conductive layer and the insulating layer are both FR-4 epoxy boards; and the adhesive layer is a PP prepreg.

[0012] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, an entire outer surface of the cable assembly is sprayed with a metallic conductive paint; and an elastic conductive sheet in contact conduction with a mating shielding structure is adhered to a surface of the metallic conductive paint.

[0013] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure,a part of a surface, extending beyond the insulating piece, of the copper busbar in each conductive layer is unsprayed with the metallic conductive paint.

[0014] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, pins in contact conduction with a mating connecting piece protrude from two ends of each copper busbar; in mounting the cable assembly, an extension portion that protrudes beyond the other insulating layers extends from the lowermost insulating layer; and the extension portion is designed to fill a gap between each pin and a mounting board, preventing a connecting screw on each pin from falling through an avoidance hole formed in the mounting board.

[0015] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, a surface of the extension portion is unsprayed with the metallic conductive paint.

[0016] For the aforementioned hard copper busbar cable assembly of the multilayer composite structure, at least one extension portion is provided with a positioning portion that is matched with a positioning structure on the mounting board to achieve rapid positioning in mounting the cable assembly. Compared with the prior art, the utility model has significant advantages and beneficial effects. By virtue of the above technical solution, the utility model can achieve considerable technical progress and practicability, has wide industrial use value, and at least has the following advantages:

[0017] The hard copper busbar cable assembly of the multilayer composite structure of the utility model improves the pressing accuracy in multi-layer hot pressing of the FR-4 epoxy board, the PP prepreg, and the copper busbar by adding the positioning structure to the copper busbar. If there are a large number of mounting sites, the copper busbar assembly is difficult in mounting positioning. The utility model adds the positioning structure on the copper busbar, so as to rapidly and accurately position the copper busbar. This significantly reduces the on-site mounting difficulty and greatly improves the mounting efficiency. The screw, as an accessory of the copper busbar, is prone to falling into a chassis in mounting, to avoid which, the FR-4 epoxy board extends around a screw mounting hole to fill a gap, thereby effectively reducing a risk of screw loss after falling. Meanwhile, to resist electromagnetic interference, spraying the surface of the FR-4 epoxy board of the copper busbar cable with the metallic conductive paint, in combination with the elastic conductive sheet, can greatly improve shielding performance of the copper busbar.

[0018] The utility model achieves multi-circuit conduction by means of the copper busbar of the multilayer composite structure, and innovatively provides two paths of copper busbars in one layer, to further increase an integration degree of the circuit of the copper busbars.BRIEF DESCRIPTION OF DRAWINGS

[0019] FIG. 1 is a lateral cross-sectional view of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 2 is a top view of the utility model with a first layer of FR-4 epoxy board removed; FIG. 3 is a top view of the utility model with a second layer of FR-4 epoxy board and a portion above it removed; FIG. 4 is a top view of the utility model with a third layer of FR-4 epoxy board and a portion above it removed; FIG. 5 is a top view of the utility model with a fourth layer of FR-4 epoxy board and a portion above it removed; FIG. 6 is a top view of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 7 is a schematic diagram of a composition of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 8 is a schematic diagram of mounting of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; FIG. 9 is a top view of a mounting state of a hard copper busbar cable assembly of a multilayer composite structure of the utility model; and FIG. 10 is a schematic diagram of a copper busbar shielding structure of a hard copper busbar cable assembly of a multilayer composite structure of the utility model. [Description of reference numerals of main elements]

[0020] 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: extension portion 10: adhesive layer 11: copper busbar 12: FR-4 epoxy board 13: central positioning hole 14: positioning pin 15: elastic conductive sheet 16: mounting board 17: conductive paint spraying region DETAILED DESCRIPTION OF THE EMBODIMENTS

[0021] To further illustrate the technical measures and effects of the utility model for achieving the intended inventive objective, the implementation manners, structures, features and effects of a hard copper busbar cable assembly of a multi-layer composite structure according to the utility model are described below in detail with reference to the accompanying drawings and preferred embodiments.

[0022] Referring to FIGs. 1 - 10, which are schematic structural diagrams of various portions of the hard copper busbar cable assembly of the multi-layer composite structure of the utility model, in which the hard copper busbar cable assembly includes 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, which are sequentially arranged from top to bottom. There is also an adhesive layer 10 between adjacent layers of the copper busbar cable assembly, i.e. between one insulating layer and its adjacent conductive layer. This adhesive layer 10 is used for connecting and fixing the insulating layer to its adjacent conductive layer. In this embodiment, the adhesive layer 10 is a PP prepreg, but it is not limited thereto. The insulating layer is an FR-4 epoxy board.

[0023] For the utility model, a central positioning hole 13 penetrating through the copper busbar cable is provided in a thickness direction of the copper busbar cable. This central positioning hole penetrates through each insulating layer, adhesive layer, and conductive layer in the thickness direction, enabling rapid positioning in stacking the stacked insulating layers and conductive layers by using a positioning pin 14 adapted to the central positioning hole 13 in stacking various layers of the copper busbar cable. This also prevents misalignment of the insulating layers, the adhesive layers, and the conductive layers under an external force after stacking, ensuring pressing accuracy and quality in hot pressing a product formed after stacking.

[0024] In an embodiment of the utility model, two copper busbars 11 are arranged in one of the first conductive layer 2, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8, with an insulating piece arranged therebetween; and the other of the above conductive layers each is provided with one copper busbar 11. The central positioning hole penetrates through the copper busbar 11 of each conductive layer. That is, if there is only one copper busbar in the conductive layer, the central positioning hole 13 penetrates through that copper busbar 11; and if there are two copper busbars 11 in the conductive layer, the central positioning hole 13 is located between the two copper busbars and penetrates through the insulating piece between the two copper busbars.

[0025] In an embodiment of the utility model, the first conductive layer 2 includes two parallel copper busbars 11, which enable conduction between two endpoints of two pathways. Without increasing a number of layers in the copper busbar cable assembly, it can enhance the circuit's transmission capacity and increase an integration degree of the copper busbar cable. The FR-4 epoxy board 12, as an insulating piece for implementing electrical isolation, is arranged between the two copper busbars 11. Since an inside diameter of the central positioning hole 13 is larger than a distance between the two copper busbars 11, the copper busbars 11 here are bent outward to form bending portions for avoiding the central positioning hole 13. The bending portions of the two copper busbars 11 are opposite in bending direction, and are both in an arc shape with its convex portion facing away from the central positioning hole 13. There is still the FR-4 epoxy board 12 between the central positioning hole 13 and the two copper busbars 11. In this embodiment, the bending portion of each copper busbar has a width consistent with those of other portions in its extension direction. This ensures a constant width of the copper busbar in its extension direction, resulting in uniform conductive performance throughout the copper busbar. Preferably, the FR-4 epoxy board 12 around the central positioning hole 13 has a width consistent with that of the FR-4 epoxy board 12 in a portion without the central positioning hole 13.

[0026] In an embodiment of the utility model, insulating pieces for implementing insulation protection are arranged on sides, facing away from each other, of the two copper busbars 11 in the first conductive layer 2. Preferably, the insulating pieces are FR-4 epoxy boards 12. As a result, the copper busbars in this conductive layer are both circumferentially covered and protected by the FR-4 epoxy boards 12. In this embodiment, the FR-4 epoxy board 12 on the side, facing away from the other copper busbar, of the copper busbar 11 remains constant in width in an extension direction of the copper busbar, and remains consistent in shape with that of an outer surface of the copper busbar on its respective side.

[0027] In the utility model, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 each includes one copper busbar and insulating pieces on two sides of the copper busbar. In this embodiment, the insulating pieces are FR-4 epoxy boards, that is, each of the above conductive layers is of a structure with one copper busbar sandwiched between two FR-4 epoxy boards. The above central positioning hole 13 penetrates through the copper busbars in the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8, enabling direct positioning of the copper busbars. There is also an annular insulating layer, supported by the FR-4 epoxy board, between the central positioning hole 13 and the copper busbars in the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8. Furthermore, to meet the requirement for the conductive performance, the copper busbar with the central positioning hole 13 protrudes outward at the central positioning hole 13 to form an arc-shaped avoidance portion. This meets the requirement for arranging the central positioning hole 13 without affecting the copper busbar's transmission performance. Preferably, the arc-shaped avoidance portions protruding from two sides of the copper busbar with the central positioning hole 13 are symmetrical; and a sum of widths of the two arc-shaped avoidance portions is equal to the width of the copper busbar in a portion without the central positioning hole. The FR-4 epoxy boards on the two sides of the copper busbar remain constant in width in the extension direction of the copper busbar, and remain consistent in shape with that of a side surface of the copper busbar.

[0028] In an embodiment of the utility model, the two copper busbars in the first conductive layer 2 form a pathway 1 and a pathway 2 for transmitting electrical signals respectively. Connecting pins 18 are formed at two ends of both the path 1 and the path 2 to facilitate conduction with a mating connecting piece. Two grounding pins 19 are formed at each end of the copper busbar in the second conductive layer 4 to provide a grounding function of the copper busbar in this layer. The copper busbar in the third conductive layer 6 forms a pathway 3 for transmitting an electrical signal. A connecting pin 18 is formed at each end of the pathway 3 for connecting with a mating connecting piece. A grounding pin 19 is formed at each end of the copper busbar in the fourth conductive layer 8 to provide the grounding function of the copper busbar in this layer. The utility model achieves the conduction function of five pathways by means of a four-layer copper busbar structure. In addition, arranging two pathways in the first conductive layer can further increase the integration degree of the copper busbar.

[0029] To rapidly and accurately positioning the copper busbar cable on the mounting board 16, the copper busbar cable of the utility model not only employs a positioning pin penetrating through the central positioning hole to be matched with a corresponding positioning hole formed in the mounting board 16 for positioning, but also is provided with at least one extension portion 91 protruding beyond other layers on the lowermost insulating layer in mounting. The at least one extension portion 91 is provided with a positioning portion that is matched with a positioning structure on the mounting board 16, providing positioning with a concave-convex structure. In mounting, the lowermost insulating layer of the copper busbar cable is either the first insulating layer or the fifth insulating layer. In this embodiment, the fifth insulating layer is arranged at a bottom and is provided with the extension portion 91. The positioning structure on the mounting board 16 is the positioning pin. The positioning portion on the extension portion 91 is either the positioning hole 911 or a positioning groove 912 that is matched with this positioning pin for positioning. The positioning hole may be a through hole formed in the extension portion 91, extending in a direction as the same as the thickness direction of the copper busbar cable. The positioning groove 912 may be an arc-shaped groove, facing the positioning pin, on one side of the extension portion.

[0030] In an embodiment of the utility model, two extension portions 91 in different extension directions are arranged on each side of the fifth insulating layer 9 in its extension direction. On one side, one of the two extension portions 91 is provided with a positioning hole 911, while the other is provided with a positioning groove 912. Preferably, centers of projections of the positioning hole 911, the positioning groove 912, and the central positioning hole 13 onto the mounting board are non-collinear. In mounting the copper busbar cable of the utility model, three positioning pins on the mounting board pass through three positioning points (i.e. the positioning hole 911, the positioning groove 912, and the central positioning hole 13). This ensures accurate positioning of the copper busbar cable on the mounting board, enabling rapid and accurate positioning of the copper busbar with the mounting board in mounting. In this way, it achieves conservation in mounting time and greatly improved mounting efficiency. The utility model incorporates a three-point positioning mounting structure, which achieves rapid and accurate positioning of the copper busbar cable with the mounting board in mounting, even in a case of a large number of mounting points.

[0031] An avoidance hole 161 is formed in the mounting board 16 corresponding to the copper busbar's pin. This allows the pin to be connected and fixed with the mating connecting portion by means of a connecting screw 20. However, in connecting and fixing the pin with the mating connecting portion, the connecting screw 20 is prone to falling into a chassis through a gap between the pin's edge and the avoidance hole 161 of the mounting board 16, making it difficult in retrieval. To prevent the connecting screw 20 from falling, in the utility model, the extension portion 91 of the fifth insulating layer is distributed beneath the pin of each copper busbar, so as to fill the gap between the copper busbar's pin and the mounting board. The extension portion 91, in correspondence to the copper busbar's pin, has a through hole 913 corresponding to a connecting and fixing portion of the copper busbar's pin, in order to connect and fix the pin with the mating connecting portion. Furthermore, a gap between the extension portion 91 and the copper busbar's pin, and a gap between the extension portion 91 and the mounting board 16 are both smaller than a minimum gap through which the connecting screw 20 can fall. This effectively prevents the connecting screw 20 from falling into the chassis.

[0032] In the utility model, the underlying FR-4 board extends to provide an anti-falling function for the screw.

[0033] In the utility model, the outer surface of the copper busbar cable is further sprayed with a metallic conductive paint, which enables conduction throughout the surface of the copper busbar cable, meaning that the copper busbar cable is enclosed by a completely closed conductive shield, providing an excellent shielding effect. An elastic conductive sheet 15 is further fixed to the surface of the metallic conductive paint. The shielding conductive sheet 15 enables shielding grounding of the overall copper busbar cable, thereby preventing electromagnetic interference. In an embodiment, the elastic conductive sheet 15 is adhered to the painted surface of a top layer of the copper busbar cable. The elastic conductive sheet is used for contact conduction with a mating shielding cover board, providing the shielding function. In other embodiments of the utility model, the elastic conductive sheet 15 may be disposed on the painted surface of the copper busbar cable at other positions, provided that it can be in contact conduction with a mating shielding structure.

[0034] In this embodiment, in spraying the conductive paint on the surface of the copper busbar cable, the surface of the copper busbar is not sprayed. That is, the surfaces, extending beyond the FR-4 epoxy board, of two ends of the copper busbar in each conductive layer are unsprayed with the conductive paint, and the extension portion 91 of the underlying insulating layer of the copper busbar cable is also unsprayed with the conductive paint.

[0035] Specifically, surfaces, not in contact to adjacent layers, of all the insulating layers and conductive layers constituting the copper busbar cable are sprayed with the conductive paint. Since the copper busbar 11 is enclosed by the FR-4 epoxy board and the adjacent insulating layer, there is no conductive paint on the surface of the copper busbar 11. The utility model combines the metallic conductive paint with the elastic conductive sheet to provide an electromagnetic shielding function of the copper busbar, thereby enhancing an anti-interference capability.

[0036] The multilayer composite hard copper busbar structure of the utility model enables effective conduction of multiple circuits within a small space, improves the pressing quality of the copper busbar, and saving a mounting time with improved mounting efficiency. Furthermore, the structure can provide screw anti-falling to prevent the screw from falling into the chassis in mounting. The electromagnetic shielding structure of the copper busbar can effectively enhance the anti-interference capability of the copper busbar.

[0037] The above are only preferred embodiments of the utility model and are not intended to limit the utility model in any form. Although the utility model has been disclosed by the preferred embodiments, it is not intended to limit the utility model. Any person familiar with the profession can make some equivalent embodiments changed or modified into equivalent change by using the technical contents disclosed above without departing from the scope of the technical solution of the utility model. However, any simple modification, equivalent change and modification made on the above embodiments according to the technical essence of the utility model without departing from the content of the technical solution of the utility model still belongs to the scope of the technical solution of the utility model.

Examples

Embodiment Construction

[0021]To further illustrate the technical measures and effects of the utility model for achieving the intended inventive objective, the implementation manners, structures, features and effects of a hard copper busbar cable assembly of a multi-layer composite structure according to the utility model are described below in detail with reference to the accompanying drawings and preferred embodiments.

[0022]Referring to FIGs. 1 - 10, which are schematic structural diagrams of various portions of the hard copper busbar cable assembly of the multi-layer composite structure of the utility model, in which the hard copper busbar cable assembly includes 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, which are sequentially arranged from top to bottom. There is also an adhesive layer 10...

Claims

1. A hard copper busbar cable assembly of a multi-layer composite structure, 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, which are stacked from top to bottom, wherein an adhesive layer for connecting and fixing one insulating layer to an adjacent conductive layer is also arranged between the two; a central positioning hole extending in a thickness direction of the copper busbar cable penetrates the stacked insulating layers, adhesive layers, and conductive layers, and is matched with a positioning pin to achieve positioning in stacking various layers; and each conductive layer comprises a copper busbar and insulating pieces located on two sides of the copper busbar.

2. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 1, wherein two copper busbars are arranged in one of the conductive layers, with an insulating piece arranged between the two copper busbars; and the other conductive layers each is provided with only one copper busbar.

3. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 2, wherein if the conductive layer is provided with two copper busbars, the central positioning hole penetrates through the insulating piece between the two copper busbars, the central positioning hole has a diameter larger than a gap between the two copper busbars, and the two copper busbars are bent away from each other at the central positioning hole; and if the conductive layer is provided with only one copper busbar, the central positioning hole penetrates through the copper busbar and is separated from the copper busbar by an annular insulating piece.

4. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 3, wherein the copper busbar and the insulating piece in one conductive layer maintain a constant width at different positions in an extending direction.

5. The hard copper busbar cable assembly of the multi-layer composite structure according to any one of claims 1 - 4, wherein the insulating piece in the conductive layer and the insulating layer are both FR-4 epoxy boards; and the adhesive layer is a PP prepreg.

6. The hard copper busbar cable assembly of the multi-layer composite structure according to any one of claims 1 - 4, wherein an entire outer surface of the cable assembly is sprayed with a metallic conductive paint; and an elastic conductive sheet in contact conduction with a mating shielding structure is adhered to a surface of the metallic conductive paint.

7. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 6, wherein a part of a surface, extending beyond the insulating piece, of the copper busbar in each conductive layer is unsprayed with the metallic conductive paint.

8. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 7, wherein pins in contact conduction with a mating connecting piece protrude from two ends of each copper busbar; in mounting the cable assembly, an extension portion that protrudes beyond the other insulating layers extends from the lowermost insulating layer; and the extension portion is designed to fill a gap between each pin and a mounting board, preventing a connecting screw on each pin from falling through an avoidance hole formed in the mounting board.

9. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 8, wherein a surface of the extension portion is unsprayed with the metallic conductive paint.

10. The hard copper busbar cable assembly of the multi-layer composite structure according to claim 8 or 9, wherein at least one extension portion is provided with a positioning portion that is matched with a positioning structure on the mounting board to achieve rapid positioning in mounting the cable assembly

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