Hard copper busbar cable assembly of multi-layer composite structure

Abstract

A hard copper busbar cable assembly of a multi-layer composite structure, the hard copper busbar cable assembly 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 a bonding layer configured to connect and fix each insulating layer and the adjacent conductive layer is further provided between the insulating layer and the adjacent conductive layer; a central positioning hole extending in a thickness direction of a copper busbar cable passes through the insulating layers, the bonding layers and the conductive layers, which are stacked, and is fitted with a positioning pin to ensure press-fit precision of the multi-layer distributed copper busbar cable during hot pressing; and each conductive layer comprises a copper busbar and insulating members located on two sides of the copper busbar, thereby achieving insulation protection. In the copper busbar cable assembly, a central positioning reference hole structure is provided, thereby improving the positioning precision during stacking of all layers, effectively increasing the press-fit precision and quality during hot pressing of a product, and also enabling all conductive copper busbars to be insulated and protected.

Description

Multi-layer composite structure rigid copper busbar cable assembly Technical Field

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

[0002] Cable assemblies are used in communications, new energy, and industrial applications, requiring electrical connections between electronic equipment systems. Traditional cable assemblies are bulky, complex, and time-consuming to install, significantly increasing the difficulty and cost of on-site wiring. Rigid copper busbar cable assemblies offer high structural integrity and simplicity, enabling rapid wiring in small spaces. This space-saving and simple installation method makes wiring quick and easy, making them widely used in highly integrated 5G base stations, new energy batteries, and other fields.

[0003] At present, when pressing together the rigid copper busbar components, it is difficult to ensure the pressing accuracy, and when there are many conductive points, the installation positioning is difficult, the installation efficiency is low, and the work efficiency is affected.

[0004] In addition, the conductive parts of the conductive layer of the existing copper busbar assembly are all exposed, which poses a safety hazard.

[0005] Summary of the Invention

[0006] In order to solve the above problems, the utility model provides a new type of multi-layer composite structure rigid copper busbar cable assembly, which has assembly positioning and insulation protection.

[0007] The purpose of the present invention and the solution to its technical problems are achieved by adopting the following technical solutions. According to the present invention, a multi-layer composite structure rigid copper busbar cable assembly is proposed, 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 stacked from top to bottom, and an adhesive layer for connecting and fixing the adjacent insulating layers and conductive layers is provided between the above-mentioned adjacent insulating layers and conductive layers; a central positioning hole extending along the thickness direction of the copper busbar cable penetrates the stacked insulating layers, adhesive layers and conductive layers, and cooperates with the positioning pins to ensure the pressing accuracy of the multi-layer copper busbar cable during hot pressing; each conductive layer includes a copper busbar and insulating parts located on both sides of the copper busbar to achieve insulation protection of the conductive layer.

[0008] The purpose of the present invention and the solution to its technical problems can be further achieved by adopting the following technical measures.

[0009] In the aforementioned multi-layer composite structure rigid copper busbar cable assembly, one of the conductive layers is provided with two copper busbars, and an insulating member is provided between the two copper busbars; the other conductive layers are provided with only one copper busbar.

[0010] In the aforementioned multi-layer composite structure rigid copper busbar cable assembly, when the conductive layer has two copper busbars, the central positioning hole passes through the insulating member between the two copper busbars, and the diameter of the central positioning hole is larger than the gap between the two copper busbars. The two copper busbars are bent away from the other copper busbar at the central positioning hole; when the conductive layer has only one copper busbar, the central positioning hole passes through the copper busbar and is separated from the copper busbar by an annular insulating member.

[0011] In the aforementioned multi-layer composite structure rigid copper busbar cable assembly, the copper busbar and insulating member of the same conductive layer maintain a constant width at different positions in the extension direction.

[0012] In the aforementioned multi-layer composite structure rigid copper busbar cable assembly, the insulating member in the conductive layer and the insulating layer are both FR-4 epoxy boards; and the bonding layer is a PP prepreg.

[0013] The aforementioned multi-layer composite structure rigid copper busbar cable assembly has metal conductive paint sprayed all over its outer surface, and an elastic conductive sheet for contacting and conducting with the matching shielding structure is pasted on the surface of the metal conductive paint.

[0014] In the aforementioned multi-layer composite structure rigid copper busbar cable assembly, the surface of the portion of the copper busbar extending out of the insulating member in each conductive layer is not sprayed with metallic conductive paint.

[0015] The aforementioned multi-layer composite structure rigid copper busbar cable assembly has pins extending from both ends of each copper busbar for connecting to the adapter connector. When the cable assembly is installed, the bottom insulation layer extends with an extension that protrudes from the other insulation layers. The extension can fill the gap between the pin and the mounting plate to prevent the connecting screws on the pin from falling through the avoidance hole on the mounting plate.

[0016] The aforementioned multi-layer composite structure rigid copper busbar cable assembly is characterized in that the surface of the extension portion is not sprayed with metallic conductive paint.

[0017] The aforementioned multi-layer composite structure rigid copper busbar cable assembly has at least one extension portion provided with at least one positioning feature for cooperating with a positioning structure on the mounting plate to quickly position the cable assembly during installation. This utility model offers significant advantages and beneficial effects over existing technologies. By utilizing the aforementioned technical solution, this utility model achieves considerable technological advancement and practicality, and has broad industrial application value, possessing at least the following advantages:

[0018] The present invention relates to a multi-layer composite structure rigid copper busbar cable assembly, which improves the pressing accuracy of the FR-4 epoxy board, PP semi-cured sheet and copper busbar during multi-layer hot pressing by adding an installation positioning structure on the copper busbar. When there are many installation points, the installation and positioning of the copper busbar assembly is difficult. The present invention achieves fast and accurate positioning of the copper busbar by adding a positioning structure on the copper busbar, effectively reducing the difficulty of on-site installation and greatly improving installation efficiency. The screws of the copper busbar accessories are prone to falling into the chassis during installation. To avoid this problem, the FR-4 epoxy board is extended around the screw mounting hole to fill the gap, effectively reducing the risk of the screw falling and being lost. At the same time, in order to resist electromagnetic interference, metal conductive paint is sprayed on the surface of the FR-4 epoxy board of the copper busbar cable, and combined with the elastic conductive sheet, the shielding performance of the copper busbar is greatly improved.

[0019] The utility model realizes the conduction function of multiple circuits through a multi-layer composite structure copper busbar, and innovatively arranges two copper busbars on the same layer, further improving the integration of the copper busbar circuit. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG1 is a transverse cross-sectional view of a multi-layer composite structure rigid copper busbar cable assembly of the present invention;

[0021] FIG2 is a top view of the present invention after removing the first layer of FR-4 epoxy board;

[0022] FIG3 is a top view of the present invention after removing the second layer of FR-4 epoxy board and the portion above it;

[0023] FIG4 is a top view of the present invention after removing the third layer of FR-4 epoxy board and the portion above it;

[0024] FIG5 is a top view of the present invention after removing the fourth layer of FR-4 epoxy board and the portion above it;

[0025] FIG6 is a top view of a multi-layer composite structure rigid copper busbar cable assembly according to the present invention;

[0026] FIG7 is a schematic diagram of the composition of a multi-layer composite structure rigid copper busbar cable assembly of the present invention;

[0027] FIG8 is a schematic diagram of the installation of a multi-layer composite structure rigid copper busbar cable assembly of the present invention;

[0028] FIG9 is a top view of the multi-layer composite structure rigid copper busbar cable assembly in the utility model in an installed state;

[0029] FIG10 is a schematic diagram of the copper busbar shielding structure of the multi-layer composite structure rigid copper busbar cable assembly of the present invention.

[0030] [Description of main component symbols] 1: First insulation layer 2: First conductive layer 3: Second insulation layer 4: Second conductive layer 5: Third insulation layer 6: Third conductive layer 7: Fourth insulation layer 8: Fourth conductive layer 9: Fifth insulation layer 91: Extension 10: Adhesive layer 11: Copper busbar 12: FR-4 epoxy board 13: Center positioning hole 14: Positioning pin 15: Elastic conductive sheet 16: Mounting plate 17: Conductive paint spraying area DETAILED DESCRIPTION

[0031] In order to further illustrate the technical means and effects adopted by the present invention to achieve the predetermined purpose of the invention, the following, in combination with the accompanying drawings and preferred embodiments, describes in detail the specific implementation method, structure, characteristics and effects of the multi-layer composite structure rigid copper busbar cable assembly proposed by the present invention.

[0032] Please refer to Figures 1-10, which are schematic diagrams of the various components of the multi-layer composite rigid copper busbar cable assembly of the present invention. This copper busbar cable assembly includes, arranged from top to bottom, 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. Adhesive layers 10 are also provided between adjacent layers of the copper busbar cable assembly, specifically between adjacent insulating and conductive layers. These adhesive layers 10 are used to securely connect adjacent insulating and conductive layers. In this embodiment, the adhesive layer 10 is a PP prepreg, but is not limited thereto. The insulating layer is an FR-4 epoxy board.

[0033] The utility model is provided with a central positioning hole 13 that penetrates the copper busbar cable along the thickness direction of the copper busbar cable. The central positioning hole penetrates each insulating layer, adhesive layer and conductive layer along the thickness direction. Therefore, when the layers of the copper busbar cable are stacked, the stacked insulating layers, adhesive layers and conductive layers can be connected together through the positioning pins 14 that are adapted to the central positioning hole 13, thereby realizing rapid positioning of the stacked insulating layers and conductive layers when stacking, and preventing the above-mentioned insulating layers, adhesive layers and conductive layers from being displaced under the action of external force after the stacking is completed, thereby ensuring the pressing accuracy and quality of the stacked product during hot pressing.

[0034] In the embodiment of the present invention, one of the first conductive layer 2, the second conductive layer 4, the third conductive layer 6, and the fourth conductive layer 8 is provided with two copper busbars 11, with an insulating member disposed between the two copper busbars; the other conductive layers each include one copper busbar 11. The central positioning hole 13 passes through the copper busbar 11 of each conductive layer. That is, when a conductive layer has only one copper busbar, the central positioning hole 13 passes through the copper busbar 11; when a conductive layer has two copper busbars 11, the central positioning hole 11 is located between the two copper busbars and passes through the insulating member between the two copper busbars.

[0035] In an embodiment of the present invention, the first conductive layer 2 includes two copper busbars 11 arranged in parallel. The two copper busbars 11 can achieve conduction between the two end points of the two paths, thereby increasing the circuit transmission capacity without increasing the number of layers of the copper busbar cable assembly and improving the integration of the copper busbar cable. An FR-4 epoxy board 12 is provided between the two copper busbars 11 to achieve insulation isolation. Since the inner diameter of the center positioning hole 13 is larger than the spacing between the two copper busbars 11, the copper busbar 11 at this location is bent outward to avoid the center positioning hole 13 to form a bent portion. The bent portions of the two copper busbars 11 bend in opposite directions and are both arc-shaped. The direction of the arc protrudes away from the center positioning hole 13, and the FR-4 epoxy board 12 is still present between the center positioning hole 13 and the two copper busbars 11. In this embodiment, the width of the copper busbar's bent portion is consistent with the width of other parts in its extension direction, so that the width of the copper busbar in its extension direction remains constant and the conductive performance is consistent at all locations. Preferably, the width of the FR-4 epoxy board 12 around the center positioning hole 13 is consistent with the width of the FR-4 epoxy board 12 where the center positioning hole 13 is not set.

[0036] In an embodiment of the present invention, both copper bars 11 of the first conductive layer 2 are provided with an insulating member on the side facing away from the other copper bar for insulation protection. Preferably, the insulating member is an FR-4 epoxy board 12, thereby ensuring that the copper bars of the conductive layer are circumferentially covered and protected by the FR-4 epoxy board 12. In this embodiment, the width of the FR-4 epoxy board 12 on the side of the copper bar facing away from the other copper bar remains constant in the direction in which the copper bar 11 extends, and its shape is consistent with the shape of the outer surface of the copper bar on the side on which it is located.

[0037] The second, third, and fourth conductive layers 4, 6, and 8 of the present invention each include a copper busbar and insulating members located on either side of the copper busbar. In this embodiment, the insulating members are FR-4 epoxy boards, meaning that each of the above conductive layers is constructed by sandwiching a copper busbar between two FR-4 epoxy boards. The aforementioned center positioning hole 13 penetrates the copper busbars in the second, third, and fourth conductive layers 4, 6, and 8, enabling direct positioning of the copper busbars. Furthermore, an annular insulating layer supported by the FR-4 epoxy board is provided between the center positioning hole 13 and the copper busbars in the second, third, and fourth conductive layers 4, 6, and 8. To ensure proper conductivity, the copper busbars with the center positioning hole 13 are convex outward at the center positioning hole 13, forming an arc-shaped relief. This, while maintaining the required center positioning hole 13 configuration, does not affect transmission performance. Preferably, the arc-shaped reliefs protruding outward on either side of the copper busbar with the center positioning hole 13 are symmetrical, and the sum of the widths of the two arc-shaped reliefs is the same as the width of the copper busbar without the center positioning hole. The width of the FR-4 epoxy boards on both sides of the copper busbar in the extension direction of the copper busbar remains constant, and the shape is consistent with the shape of the side surface of the copper busbar.

[0038] In an embodiment of the present invention, the two copper bars of the first conductive layer 2 respectively form a path 1 and a path 2 for transmitting electrical signals, and connecting pins 18 are formed at both ends of the path 1 and the path 2 to facilitate conduction with the adapter connector. Two grounding pins 19 are respectively formed at both ends of the copper bar of the second conductive layer 4 for realizing the grounding function of the copper bar of this layer. The copper bar of the third conductive layer 6 forms a path 3 for transmitting electrical signals, and a connecting pin 18 is respectively formed at both ends of the path 3, and the connecting pin is used to connect with the adapter connector. A grounding pin 19 is respectively formed at both ends of the copper bar of the fourth conductive layer 8 for realizing the grounding function of the copper bar of this layer. The present invention realizes the conduction function of 5 paths through a four-layer copper bar structure, and two paths are arranged on the copper bar of the first conductive layer, so that the integration of the copper bar is further improved.

[0039] To achieve quick and accurate positioning of the copper busbar cable on the mounting plate 16, the copper busbar cable of the present invention is not only positioned by means of a positioning pin inserted through a central positioning hole that cooperates with a corresponding positioning hole on the mounting plate 16, but also has at least one extension 91 protruding from the other layers on the bottommost insulating layer of the copper busbar cable during installation. At least one extension 91 is provided with a positioning portion for cooperating with the positioning structure on the mounting plate 16 to achieve concave-convex structural positioning. The bottommost insulating layer of the copper busbar cable during installation is the first insulating layer or the fifth insulating layer. In this embodiment, the fifth insulating layer is located at the bottommost layer and is provided with the extension 91. The positioning structure on the mounting plate 16 is a positioning pin, and the positioning portion provided on the extension 91 is a positioning hole 911 or a positioning groove 912 that cooperates with the positioning pin for positioning. The positioning hole can be a through hole on the extension 91 whose extension direction is consistent with the thickness direction of the copper busbar cable, and the positioning groove 912 can be an arc-shaped groove located on one side of the extension facing the positioning pin.

[0040] In an embodiment of the present invention, two extension portions 91 with different extension directions are respectively provided on both sides of the extension direction of the fifth insulating layer 9, wherein one of the two extension portions 91 on one side is provided with a positioning hole 911, and the other is provided with a positioning groove 912. Preferably, the centers of the projections of the positioning hole 911, the positioning groove 912 and the center positioning hole 13 on the mounting plate are not collinear. When the copper busbar cable of the present invention is installed, the three positioning pins on the mounting plate pass through the three positioning points (positioning hole 911, positioning groove 912 and center positioning hole 13), and the copper busbar cable is accurately positioned on the mounting plate, realizing fast and accurate positioning of the copper busbar with the mounting plate during installation, saving installation time and greatly improving installation efficiency. The present invention is provided with a three-point positioning installation structure, which realizes fast and accurate positioning of the copper busbar cable with the mounting plate during installation when there are many installation points.

[0041] The mounting plate 16 is provided with avoidance holes 161 at positions corresponding to the copper busbar pins, so as to facilitate the connection and fixation of the pins with the adapter connection portion by the connecting screws 20. When the pins are connected and fixed with the adapter connection portion, the connecting screws 20 are likely to fall through the gap between the pin edge and the avoidance holes 161 of the mounting plate 16, entering the interior of the chassis, making it difficult to remove. To prevent the connection screws 20 from falling, the extensions 91 of the fifth insulating layer of the present invention are distributed under the pins of each copper busbar, which can fill the gap between the copper busbar pins and the mounting plate. The positions of the extensions 91 corresponding to the copper busbar pins are provided with through holes 913 corresponding to the connection and fixation parts of the copper busbar pins, so as to facilitate the connection and fixation of the pins with the adapter connection portion. The gaps between the extensions 91 and the copper busbar pins and the gaps between the extensions 91 and the mounting plate 16 are both smaller than the minimum gap through which the connecting screws 20 can fall, thereby preventing the connecting screws 20 from falling into the chassis.

[0042] The utility model extends the bottom FR-4 board to realize the function of preventing the screws from falling off.

[0043] The outer surface of the copper busbar cable of the present invention is also sprayed with metal conductive paint, which makes the surface of the copper busbar cable conductive everywhere, that is, the copper busbar cable is surrounded by a completely enclosed conductive shield, which has a good shielding effect. In addition, an elastic conductive sheet 15 is fixed to the surface of the metal conductive paint. The shielding conductive sheet 15 is used to achieve the overall shielding and grounding of the copper busbar cable to avoid electromagnetic interference. In an embodiment, the elastic conductive sheet 15 is bonded to the painted surface of the top layer of the copper busbar cable and is used to contact and conduct with the matching shielding cover to achieve a shielding function. In other embodiments of the present invention, the elastic conductive sheet 15 can be arranged on the painted surface of other positions of the copper busbar cable, so that it can contact and conduct with the matching shielding structure.

[0044] In this embodiment, when the surface of the copper busbar cable is sprayed with conductive paint, the surface of the copper busbar is not sprayed, that is, the surfaces of the parts of the copper busbars at both ends of each conductive layer extending out of the FR-4 epoxy board are not sprayed with conductive paint, and the extended part 91 of the bottom insulation layer of the copper busbar cable is not sprayed with conductive paint either.

[0045] Specifically, the surfaces of each insulating and conductive layer that don't contact adjacent layers of the copper busbar cable are sprayed with conductive paint. However, since copper busbar 11 is surrounded by the FR-4 epoxy board and adjacent insulating layers, no conductive paint remains on its surface. This new design combines metallic conductive paint with an elastic conductive sheet to achieve electromagnetic shielding for the copper busbar, enhancing its anti-interference capabilities.

[0046] The multi-layer composite hard copper busbar structure of this utility model can realize the effective conduction of multiple circuits in a smaller space; improve the pressing quality of the copper busbar; save installation time and improve installation efficiency; and the structure can prevent the screws from falling off, avoiding the screws from falling into the chassis during installation; the electromagnetic shielding structure of the copper busbar effectively improves the anti-interference ability of the copper plate.

[0047] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with this profession can make some changes or modifications to equivalent embodiments of the technical content disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A multi-layer composite structure rigid copper busbar cable assembly, characterized in that: It 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, and an adhesive layer for connecting and fixing the adjacent insulating layers and conductive layers is also provided between the above-mentioned adjacent insulating layers and conductive layers; a central positioning hole extending along the thickness direction of the copper bus cable penetrates the above-mentioned stacked insulating layers, adhesive layers and conductive layers, and cooperates with the positioning pins to realize the positioning of each layer when stacked; each conductive layer includes a copper bus and insulating parts located on both sides of the copper bus.

2. The multi-layer composite structure rigid copper busbar cable assembly according to claim 1, characterized in that: One of the above-mentioned conductive layers is provided with two copper bars, and an insulating member is provided between the two copper bars; the other conductive layers are only provided with one copper bar.

3. The multi-layer composite structure rigid copper busbar cable assembly according to claim 2, characterized in that: When there are two copper bars in the conductive layer, the central positioning hole passes through the insulating member between the two copper bars, and the diameter of the central positioning hole is larger than the gap between the two copper bars, and the two copper bars are bent away from the other copper bar at the central positioning hole; when there is only one copper bar in the conductive layer, the central positioning hole passes through the copper bar and there is an annular insulating member between the copper bar and the central positioning hole.

4. The multi-layer composite structure rigid copper busbar cable assembly according to claim 3, characterized in that: The copper busbars and insulating members of the same conductive layer maintain constant width at different positions in the extension direction.

5. The multi-layer composite structure rigid copper busbar cable assembly according to any one of claims 1 to 4, characterized in that: The insulating member and the insulating layer in the conductive layer are both FR-4 epoxy boards; the bonding layer is a PP prepreg.

6. The multi-layer composite structure rigid copper busbar cable assembly according to any one of claims 1 to 4, characterized in that: Metallic conductive paint is sprayed everywhere on the outer surface of the cable assembly, and an elastic conductive sheet for contacting and conducting with an adapted shielding structure is pasted on the surface of the metallic conductive paint.

7. The multi-layer composite structure rigid copper busbar cable assembly according to claim 6, characterized in that: The surface of the portion of the copper busbar extending out of the insulating member in each conductive layer is not sprayed with metal conductive paint.

8. The multi-layer composite structure rigid copper busbar cable assembly according to claim 7, characterized in that: Pins for connecting to the adapter connector are extended from both ends of each copper busbar. When the cable assembly is installed, the bottommost insulating layer extends an extension that protrudes from other insulating layers. The extension can fill the gap between the pin and the mounting plate to prevent the connecting screws on the pin from falling from the avoidance hole on the mounting plate.

9. The multi-layer composite structure rigid copper busbar cable assembly according to claim 8, characterized in that: The surface of the extension portion is not sprayed with metal conductive paint.

10. The multi-layer composite structure rigid copper busbar cable assembly according to claim 8 or 9, characterized in that: At least one of the extension parts is provided with a positioning part for cooperating with the positioning structure on the mounting plate to realize rapid positioning of the cable assembly during installation.

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