Laminated copper busbars and copper busbar assemblies

Abstract

This invention relates to a stacked copper busbar and a copper busbar assembly. The stacked copper busbar includes: a first insulating member, a first copper busbar, a second insulating member, a second copper busbar, a third insulating member, a third copper busbar, and a fourth insulating member, which are sequentially stacked along a second direction and extending along a first direction. The first, second, and third copper busbars each have a connector on their third-direction upward-facing side. A housing surrounds the first, first, second, second, third, third, and fourth insulating members from opposite outer sides along the second direction and from the other third-direction upward-facing side of each insulating member. This stacked copper busbar has a compact structure and can meet the safety clearance and creepage distance requirements under high voltage and high current conditions.

Claims

1. A laminated copper busbar (10a, 10b), characterized in that it comprises: A first insulating component (141), a first copper busbar (11), a second insulating component (142), a second copper busbar (12), a third insulating component (143), a third copper busbar (13), and a fourth insulating component (144) are stacked sequentially along a first direction and a second direction. The first copper busbar (11), the second copper busbar (12), and the third copper busbar (13) are respectively provided with a plug-in interface on the third-direction upward side. The outer shell (17) of the first insulating component (141), the first copper busbar (11), the second insulating component (142), the second copper busbar (12), the third insulating component (143), the third copper busbar (13), and the fourth insulating component (144) is wrapped from the opposite outer side of the first insulating component (141) and the fourth insulating component (144) in the second direction and from the other third-direction upward side of the first insulating component (141), the first copper busbar (11), the second insulating component (142), the second copper busbar (12), the third insulating component (143), the third copper busbar (13), and the fourth insulating component (144).

2. The multilayer copper busbars (10a, 10b) as described in claim 1, wherein, Slots (15) are formed between the first insulating member (141) and the second insulating member (142), between the second insulating member (142) and the third insulating member (143), and between the third insulating member (143) and the fourth insulating member (144). The first copper busbar (11), the second copper busbar (12), and the third copper busbar (13) are respectively locked in the slots (15).

3. The multilayer copper busbars (10a, 10b) as described in claim 2, wherein, The first insulating member (141), the second insulating member (142), the third insulating member (143) and the fourth insulating member (144) are respectively connected to each other on the other side of the third direction by the mating of the groove (145) and the protrusion (146).

4. The multilayer copper busbars (10a, 10b) as described in claim 1, wherein, The outer casing (17) has a first side plate (171) and a second side plate (172) located on opposite outer sides of the first insulating member (141) and the second insulating member (142) in a second direction, and a connecting plate (173) connected to the other side of the first side plate (171) and the second side plate (172) in a third direction. The first side plate (171) and the second side plate (172) are also fixed with a first grounding block (181) and a second grounding block (182) respectively on opposite inner sides of the first side plate (171) and the second side plate (172).

5. A copper busbar device (100), characterized in that it comprises: A first stacked copper busbar (10a) and a second stacked copper busbar (10b) extending along a first direction and offset in a third direction, wherein the first stacked copper busbar (10a) and the second stacked copper busbar (10b) are both stacked copper busbars (10a, 10b) as described in any one of claims 1 to 4; a connecting busbar assembly (20, 20') in which the first copper busbar (11), the second copper busbar (12) and the third copper busbar (13) at opposite ends in the first direction of the first stacked copper busbar (10a) and the second stacked copper busbar (10b) overlap in a third direction.

6. The copper busbar device (100) as described in claim 5, wherein, The connecting bus assembly (20, 20') includes a first connecting flexible copper bus (21) that overlaps two first copper buses (11) of the first stacked copper bus (10a) and the second stacked copper bus (10b), a second connecting flexible copper bus (22) that overlaps two second copper buses (12) of the first stacked copper bus (10a) and the second stacked copper bus (10b), and a third connecting flexible copper bus (23) that overlaps two third copper buses (13) of the first stacked copper bus (10a) and the second stacked copper bus (10b).

7. The copper busbar device (100) as described in claim 6, wherein, The first connecting flexible copper busbar (21) overlaps the outside of the two first copper busbars (11) of the first stacked copper busbar (10a) and the second stacked copper busbar (10b), and the third connecting flexible copper busbar (23) overlaps the outside of the two third copper busbars (13) of the first stacked copper busbar (10a) and the second stacked copper busbar (10b). The first connecting flexible copper busbar (21) and the second connecting flexible copper busbar (22) both include a middle section (231) extending along a third direction, a first bent section (232) and a second bent section (233) bending inward along a third direction from both ends of the middle section (231), and a third bent section (233) extending inward from the first bent section (232) along a third direction. The first connecting section (234) extends in the first direction and the second connecting section (235) extends in the third direction from the second bending section (233) in the opposite direction. The first connecting section (234) has a first waist-shaped hole (236) extending in one of the first and third directions, which is connected to the outside of the first copper busbar (11) or the third copper busbar (13) of the first stacked copper busbar (10a) by a pin. The second connecting section (235) has a second waist-shaped hole (237) extending in the other of the first and third directions, which is connected to the outside of the first copper busbar (11) or the third copper busbar (13) of the second stacked copper busbar (10b) by a pin. The second connecting soft copper busbar (22) is a straight line. The overlapping end of the second copper busbar (12) of the first stacked copper busbar (10a) is welded and fixed with a first connecting hard copper busbar (24) extending towards the second stacked copper busbar (10b) in a third direction. The overlapping end of the second copper busbar (12) of the second stacked copper busbar (10b) is welded and fixed with a second connecting hard copper busbar (25) extending towards the first stacked copper busbar (10a) in a third direction. The first connecting hard copper busbar (24) is provided with a third waist-shaped hole (241) extending in one of the first direction and the third direction, which is connected to one end of the second connecting soft copper busbar (22) by a pin. The second connecting hard copper busbar (25) is provided with a fourth waist-shaped hole (251) extending in the other of the first direction and the third direction, which is connected to the other end of the second connecting soft copper busbar (22) by a pin.

8. The copper busbar device (100) as described in claim 7, wherein, An overlap groove is provided on one side of the second direction of the overlap end of the second copper busbar (12). The first connecting hard copper busbar (24) and the second connecting hard copper busbar (25) are respectively welded and fixed in the overlap groove. The two ends of the second connecting soft copper busbar (22) overlap on the other side of the second direction of the first connecting hard copper busbar (24) and the second connecting hard copper busbar (25).

9. The copper busbar device (100) as described in claim 6, wherein, The first connecting flexible copper busbar (21) and the second connecting flexible copper busbar (22) are both straight. One end of the first connecting flexible copper busbar (21) and the second connecting flexible copper busbar (22) is provided with a first waist-shaped hole (236) extending in one of the first direction and the third direction, and the other end is provided with a second waist-shaped hole (237) extending in the other of the first direction and the third direction. The two ends of the first connecting flexible copper busbar (21) overlap the outer side of the two first copper busbars (11) of the first stacked copper busbar (10a) and the second stacked copper busbar (10b) away from the second copper busbar (12). The two ends of the second connecting flexible copper busbar (22) overlap the side of the two second copper busbars (12) of the first stacked copper busbar (10a) and the second stacked copper busbar (10b) away from the first copper busbar (11). The third connecting soft copper busbar (23) includes a middle section (231) extending along a third direction, a first bent section (232) and a second bent section (233) bending inward from both ends of the middle section (231) along a first direction, a first connecting section (234) extending from the first bent section (232) along a first direction, and a second connecting section (235) extending in the opposite direction from the second bent section (233) along the first direction. The first connecting section (234) is provided with a first waist-shaped hole (236) extending along one of the first and third directions, which is connected to the outside of the third copper busbar (13) of the first stacked copper busbar (10a) by a pin. The second connecting section (235) is provided with a second waist-shaped hole (237) extending along the other of the first and third directions, which is connected to the outside of the third copper busbar (13) of the second stacked copper busbar (10b) by a pin.

10. The copper busbar device (100) as claimed in claim 6, wherein, The first connecting soft copper busbar (21), the second connecting soft copper busbar (22) and the third connecting soft copper busbar (23) are all made of multiple layers of flexible soft copper busbars pressed together, and are wrapped with heat shrink tubing.

11. The copper busbar device (100) as claimed in claim 5, wherein, The copper busbar device (100) further includes a protective shell (30) covering the connecting busbar assembly (20) and its overlapping portion with the first stacked copper busbar (10a) and the second stacked copper busbar (10b), and the protective shell (30) is provided with ventilation holes (36) around its perimeter.

12. The copper busbar device (100) as claimed in claim 11, wherein, The protective shell (30) has a first insulating sheet (34) and a second insulating sheet (35) respectively on both sides of the connecting row assembly (20) in the first direction.

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