Busbar structure having side-by-side configuration

Abstract

A busbar structure having a side-by-side configuration, comprising a first busbar conductor (1) and a second busbar conductor (2). The first busbar conductor (1) and the second busbar conductor (2) are arranged side by side, an insulating gap (7) is formed between the first busbar conductor (1) and the second busbar conductor (2), and the height of the insulating gap is less than or equal to the length of the shortest side of each of the first busbar conductor (1) and the second busbar conductor (2). The first busbar conductor (1) and the second busbar conductor (2) each are provided with an exposed section (3) and an insulated section (4), the insulated section (4) is covered by an insulating layer (5) to implement insulation and positioning, and part of the insulating layer (5) is filled in the insulating gap (7) to achieve insulation between the first busbar conductor (1) and the second busbar conductor (2), so that the depth of the insulating gap between the two conductors is shortened, and an insulating material between the two conductors is more easily fully filled and uniformly distributed.

Description

Parallelly arranged busbar structure TECHNICAL FIELD

[0001] The utility model relates to the field of charger, more specifically, it relates to a parallelly arranged busbar structure. BACKGROUND

[0002] The busbar has positive and negative poles and is used for connecting a circuit to form a passage. The busbar provides excellent overcurrent capacity and reliable connection mechanical properties.

[0003] In the related art, the conductors corresponding to the positive and negative poles of the busbar are often arranged up and down, which has certain limitations in production process, electromagnetic shielding effect and space arrangement. For example, the insulating material is difficult to be uniformly distributed when the conductors arranged in upper and lower layers are extruded; after the insulation is peeled off, the operation of inserting the connector is complex in the subsequent processing; at the same time, this design is not conducive to the bending and space arrangement of the busbar.

[0004] Therefore, how to design a new type of busbar structure to overcome the above technical problems, improve production efficiency, optimize space arrangement and improve electromagnetic shielding effect has become a problem to be solved in the field. SUMMARY

[0005] The utility model provides a parallelly arranged busbar structure for optimizing the conductor layout mode.

[0006] In order to solve the above technical problems, the utility model adopts the following technical scheme:

[0007] A parallelly arranged busbar structure comprises a first busbar conductor and a second busbar conductor, the first busbar conductor and the second busbar conductor are arranged side by side, and the first busbar conductor and the second busbar conductor have an insulating gap therebetween, the height of the insulating gap is less than or equal to the shortest side length of the first busbar conductor and the second busbar conductor.

[0008] The first busbar conductor and the second busbar conductor have an exposed section and an insulating section, the insulating section is wrapped by an insulating layer to realize insulation and positioning, and part of the insulating layer is filled in the insulating gap to provide insulation between the first busbar conductor and the second busbar conductor.

[0009] The posture of the first busbar conductor and the second busbar conductor makes the path of the insulating material entering the insulating gap between them the shortest, so that uniform distribution can be realized. The parallelly arranged conductors are easier to assemble, reducing the operation difficulty. The parallelly arranged conductors make the thickness of the formed busbar structure smaller, easy to bend and easy to arrange in space, making the whole more compact and flexible. The insulating layers arranged outside in sequence provide insulation, and the shielding layer of the outer layer shields electromagnetic waves, avoiding the influence of electromagnetic waves generated by overcurrent on external equipment.

[0010] As preferred, the insulating layer is further provided with a shielding layer, which is an integrally formed metal sleeve or a continuous metal shielding layer formed by continuously wrapping a metal strip and longitudinally continuously welding.

[0011] As preferred, the first busbar conductor and the second busbar conductor are located on the same horizontal plane. In this preferred mode, the height or depth of the insulating gap is consistent with the length of the shortest side of the conductor, and the cross section of the insulating gap is consistent from top to bottom, so that the insulating material is easy to flow in and achieve uniform distribution, thereby improving the yield.

[0012] As preferred, the first busbar conductor and the second busbar conductor are obliquely arranged, so that the cross section of the insulating gap gradually decreases from one end to the other end. The included angle between the two conductors is an obtuse angle close to 180 degrees, which produces an insulating gap with one large end and one small end. The insulating material can flow in from the large end and converge with the insulating material outside the insulating gap at the small end, so that the insulating material enters the insulating gap faster, thereby improving the production efficiency.

[0013] As preferred, the edges of the first busbar conductor and the second busbar conductor have smooth transition chamfers. In addition to aesthetics and structural reinforcement, the structure can also increase the opening size of the insulating gap, so that the insulating material is easy to flow in and achieve uniform distribution, thereby improving the yield.

[0014] As preferred, the cross-sectional shape of the first busbar conductor and the second busbar conductor is any one of a plurality of straight lines connected and surrounded, a plurality of arc lines connected and surrounded, and an arc line and a straight line connected and surrounded.

[0015] As preferred, the material of the first busbar conductor and the second busbar conductor is any one of copper, copper alloy, aluminum, aluminum alloy, and copper-aluminum composite material.

[0016] As preferred, the material of the insulating layer is any one of TPE, PA12, PVC, EVA, PE, PPS, PET, PBT, PI, and silicone rubber.

[0017] As preferred, the insulating material between the insulating gaps includes a combination of one or more of polytetrafluoroethylene and polyimide. The material enhances the insulation performance between the two conductors.

[0018] As preferred, the material of the shielding layer is any one of copper, copper alloy, aluminum, aluminum alloy, copper-aluminum composite material, and stainless steel.

[0019] Compared with the prior art, the utility model has the beneficial effects that:

[0020] (1) shorten the depth of the insulation gap between the two conductors, so that the insulation material between them is filled and evenly distributed;

[0021] (2) when positioning and injection molding the two conductors, the operation is easier;

[0022] (3) the side-by-side arrangement is easier to bend and arrange in space, improving space utilization;

[0023] (4) higher assembly efficiency, faster production rhythm;

[0024] (5) the shielding performance is better in the transverse direction than in the longitudinal direction. BRIEF DESCRIPTION OF DRAWINGS

[0025] Fig. 1 is a front view of the present application;

[0026] Fig. 2 is a left view of the present application;

[0027] Fig. 3 is a schematic diagram under another embodiment of the present application;

[0028] Fig. 4 is a schematic diagram under another embodiment of the present application

[0029] In the drawings:

[0030] The first busbar conductor 1, the second busbar conductor 2, the exposed section 3, the insulation section 4, the insulation layer 5, the shielding layer 6, the insulation gap 7. DETAILED DESCRIPTION

[0031] The present disclosure will be further described below in conjunction with the drawings and embodiments.

[0032] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the present application. Unless otherwise indicated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application pertains.

[0033] It should be noted that the terms used herein are only for the purpose of describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise, and furthermore, it should be understood that when the terms "comprise" and / or "include" are used in the specification, there is a presence of the features, steps, operations, devices, components and / or combinations thereof.

[0034] In the present disclosure, the terms such as "fixedly connected", "connected", "connected" and the like should be broadly understood, which can be fixedly connected, integrally connected or detachably connected; it can be directly connected or indirectly connected through an intermediate medium. For relevant scientific research or technical personnel in the art, the specific meaning of the above terms in the present disclosure can be determined according to the specific circumstances, and cannot be understood as a limitation on the present disclosure. Embodiments

[0035] A parallelly arranged busbar structure, as shown in FIG. 1, includes a first busbar conductor 1 and a second busbar conductor 2, the first busbar conductor 1 and the second busbar conductor 2 are arranged side by side, and the first busbar conductor 1 and the second busbar conductor 2 have an insulating gap 7, the height of the insulating gap 7 is less than or equal to the shortest side length of the first busbar conductor 1 and the second busbar conductor 2;

[0036] The first busbar conductor 1 and the second busbar conductor 2 have an exposed section 3 and an insulating section 4, the insulating section 4 is wrapped by an insulating layer 5 to achieve insulation and positioning, and part of the insulating layer 5 is filled in the insulating gap 7 to provide insulation between the first busbar conductor 1 and the second busbar conductor 2;

[0037] The insulating layer 5 is further provided with a shielding layer 6.

[0038] The material of the first busbar conductor 1 and the second busbar conductor 2 is any one of copper, copper alloy, aluminum, aluminum alloy, and copper-aluminum composite material, and is preferably aluminum.

[0039] The insulating layer 5 is wrapped around the insulating section 4 of the first busbar conductor 1 and the second busbar conductor 2 by extrusion coating, and the insulating material also enters the insulating gap 7 to provide insulation between the first busbar conductor 1 and the second busbar conductor 2.

[0040] The material of the insulating layer 5 is any one of TPE, PA12, PVC, EVA, PE, PPS, PET, PBT, PI, and silicone rubber. It is realized by extrusion coating or heat shrinkage, has good insulation performance and mechanical strength, can ensure that the insulating material closely adheres to the surface of the conductor, and improves the overall insulation performance. In some embodiments, the formation of the continuous extrusion insulating layer is a key step. The following are the main steps of the insulating layer production:

[0041] Material preparation: first, select suitable insulating materials. Common insulating materials include high molecular polymers, rubber or plastic, etc., which have good insulation performance and heat resistance. At the same time, prepare the aluminum busbar, ensure that the surface is clean and free of impurities, so that the insulating layer can be closely adhered.

[0042] Pre-treatment: pre-treat the surface of the aluminum busbar, such as cleaning, degreasing, rust removal, etc., to ensure that the surface is flat and clean, and to improve the bonding force between the insulating layer and the aluminum busbar.

[0043] Continuous extruder setup: Place the selected insulation material into the hopper of the continuous extruder and adjust the parameters of the extruder such as extrusion speed, temperature, etc. according to the desired insulation layer thickness.

[0044] Extrusion process: Start the continuous extruder, and under the action of heating and extrusion, the first busbar conductor 1 and the second busbar conductor 2 are continuously extruded through the mold at the same time, forming an insulation layer matching the cross-sectional shape of the first busbar conductor 1 and the second busbar conductor 2. The softened insulation material will flow into the insulation gap 7 between the first busbar conductor 1 and the second busbar conductor 2 due to the chamfer and gap between them. The insulation material will eventually wrap the first busbar conductor 1 and the second busbar conductor 2 inside, forming a whole, and isolating the first busbar conductor 1 and the second busbar conductor 2 from each other. At the same time, the insulation material should ensure that the insulation layer is uniformly and continuously wrapped on the surface of the aluminum busbar during the extrusion process.

[0045] Cooling and solidification: The extruded insulation layer is quickly cooled by the cooling device to make it solidify and remain stable. The cooling method can be air cooling or water cooling, and the appropriate cooling method is selected according to the characteristics of the insulation material.

[0046] The continuous extrusion process has significant advantages in production efficiency, quality stability, cross-sectional shape diversity, mechanical properties, dimensional accuracy, and cost savings.

[0047] In some embodiments, it can also be realized in the form of injection molding, which uses multiple injection molding. First, use materials with better insulation performance such as polytetrafluoroethylene, polyimide, etc. to injection mold in the insulation gap 7, and then injection mold outside the first busbar conductor 1 and the second busbar conductor 2. The insulation material between the insulation gap 7 and the insulation material wrapped around the first busbar conductor 1 and the second busbar conductor 2 forms a whole.

[0048] The first busbar conductor 1 and the second busbar conductor 2 serve as positive and negative conductors respectively. During production, the first busbar conductor 1 and the second busbar conductor 2 are placed side by side in the mold, and the insulation material directly enters the mold to integrate the positive and negative electrodes, improving production efficiency.

[0049] The cross-sectional shape of the first busbar conductor 1 and the second busbar conductor 2 is any one of a plurality of straight lines connected and surrounded, a plurality of arc lines connected and surrounded, and an arc line and a straight line connected and surrounded. In the present embodiment, the cross-sectional shape is rectangular. The edges of the first busbar conductor 1 and the second busbar conductor 2 have chamfers with smooth transitions. In addition to aesthetics and structural reinforcement, the structure can also increase the opening size of the insulation gap 7, making it easier for the insulation material to flow in and achieve uniform distribution, improving yield, optimizing electromagnetic shielding effect. As shown in FIG. 4, in a preferred embodiment, the cross-sectional shape of the first busbar conductor 1 and the second busbar conductor 2 is semicircular at both ends, further reducing the depth of the insulation gap and making it more aesthetically pleasing. The semicircular shape makes it easier to calculate the cross-sectional area, making it easier to calculate the upper limit of the current it can withstand. When used in new energy vehicles, the end of the busbar is provided with a sealing ring and a connector, and the cross-sectional shape of the busbar with semicircular ends has better packaging and sealing effect, and the sealing ring on both sides of the busbar end is more evenly compressed, which is more conducive to sealing. The R angle of the square edge is smaller, and the sealing effect after compression is slightly worse than that of the round edge.

[0050] In the present embodiment, the shielding layer 6 is a one-piece metal sleeve or a continuous metal shielding layer 6 formed by continuous wrapping of a metal strip and longitudinal continuous welding. The structure not only provides shielding but also protects the insulation layer 5, improving the stability and reliability of the device. Specifically, the busbar conductor, except for the connection part at both ends of the conductive material, is formed into a continuous full coverage outside the insulation layer by a continuous bending and welding process of a metal sheet, or a continuous full coverage by a seamless metal tube shrinking process. The busbar conductor after shielding full coverage can be bent in the width direction, bent in the thickness direction, or twisted and bent along the center line direction according to design requirements, to adapt to the different installation space and layout requirements of new energy vehicles.

[0051] For the metal strip wrapping shielding scheme, the side-by-side arrangement has the advantage of improving the shielding effect compared to the up-and-down arrangement. The metal strip includes a notch with a relatively fixed width. The smaller the width of the notch relative to the overall width, the better the shielding effect. It is usually arranged on the maximum side of the conductor cross-section, and the side-by-side arrangement of the present application can further increase the width of the maximum side, so that the width of the notch relative to the maximum side is smaller, thereby optimizing the shielding effect.

[0052] The material of the shielding layer 6 is any one of copper, copper alloy, aluminum, aluminum alloy, copper-aluminum composite material, and stainless steel. In a preferred embodiment, it is aluminum. The aluminum sheet is welded outside the insulation layer and forms an integral part after stretching and shaping, so that the aluminum sheet can serve as both an electromagnetic shielding layer 6 and a protective layer for the aluminum busbar insulation.

[0053] In the production process, the insulating layer 5 and the shielding layer 6 are arranged on the first busbar conductor 1 and the second busbar conductor 2 in sequence. Among them, the insulating layer 5 and the shielding layer 6 can be covered on the whole section of the first busbar conductor 1 and the second busbar conductor 2 and then removed to expose the exposed section 3; or the insulating section 4 corresponding part can be directly injection molded and covered by the shielding layer 6. Among them, the example in Figure 1 is to show the insulating layer 5, and in actual production, the shielding layer 6 should completely cover the side wall of the insulating layer 5.

[0054] The connection of the exposed section 3 and the external electrical structure is realized by including electroplating process (such as nickel plating, tin plating, copper plating, silver plating or ultrasonic tin plating), polymer diffusion welding process, soldering process, stirring welding process or riveting copper nut process, etc. to improve the mechanical and electrical properties.

[0055] As shown in Figure 2, in some embodiments, the first busbar conductor 1 and the second busbar conductor 2 are located on the same horizontal plane. In this preferred mode, the height or depth of the insulating gap 7 is consistent with the length of the shortest side of the conductor, and the cross section of the insulating gap 7 is consistent from top to bottom, and the insulating material is easy to flow into and achieve uniform distribution, improving the yield.

[0056] As shown in Figure 3, in another embodiment, the first busbar conductor 1 and the second busbar conductor 2 are arranged obliquely, so that the cross section of the insulating gap 7 gradually decreases from one end to the other end. The included angle between the two conductors is an obtuse angle close to 180 degrees, which produces an insulating gap 7 with one large end and one small end, so that the insulating material can flow from the large end and converge with the insulating material outside the insulating gap 7 at the small end, so that the speed of the insulating material entering the insulating gap 7 is faster, improving the production efficiency. In the scheme, the height of the insulating gap 7 is shorter than the shortest side.

[0057] By adopting the design of double conductors arranged left and right, and combining the optimized wrapping of high-voltage insulating layer and shielding layer 6, the high-voltage shielding busbar structure of the embodiment realizes excellent electromagnetic shielding effect, high insulation performance and high space utilization. At the same time, the production process is simplified, the production efficiency is improved, and strong technical support is provided for the development of power transmission and distribution field.

[0058] The above embodiments are only the preferred embodiments of the present application, and do not limit the present application in any form. Other variants and modifications can be made without exceeding the technical solutions recited in the claims.

Claims

1. A busbar structure arranged side by side, characterized in that The first busbar conductor and the second busbar conductor are arranged side by side, and have an insulating gap therebetween, the height of the insulating gap being less than or equal to the shortest side length of the first busbar conductor and the second busbar conductor; The first busbar conductor and the second busbar conductor have an exposed section and an insulated section, the insulated section being insulated and positioned by an insulating layer, and part of the insulating layer being filled in the insulating gap to provide insulation between the first busbar conductor and the second busbar conductor.

2. The parallel bus structure of claim 1, wherein, The insulating layer is further provided with a shielding layer, which is an integrally formed metal sleeve or a continuous metal shielding layer formed by continuously wrapping a metal strip and longitudinally continuously welding.

3. The parallel bus structure of claim 1, wherein, The first busbar conductor and the second busbar conductor are located on the same horizontal plane.

4. The parallel bus structure of claim 1, wherein, The first busbar conductor and the second busbar conductor are arranged obliquely, so that the cross section of the insulating gap gradually decreases from one end to the other end.

5. A busbar structure according to claim 3 or 4, c h a r a c t e r i s e d in that The edges of the first busbar conductor and the second busbar conductor have a smooth transition chamfer.

6. The parallel bus structure of claim 1 wherein, The cross-sectional shape of the first busbar conductor and the second busbar conductor is any one of a plurality of straight lines connected and surrounded, a plurality of arc lines connected and surrounded, and an arc line and a straight line connected and surrounded.

7. The parallel bus structure of claim 1 wherein, The material of the first busbar conductor and the second busbar conductor is any one of copper, copper alloy, aluminum, aluminum alloy, and copper-aluminum composite material.

8. The parallel bus structure of claim 1 wherein, The material of the insulating layer is any one of TPE, PA12, PVC, EVA, PE, PPS, PET, PBT, PI, and silicone rubber.

9. The parallel bus structure of claim 8, wherein, The insulating material between the insulating gaps includes a combination of one or more of polytetrafluoroethylene and polyimide.

10. The parallel bus structure of claim 2, wherein, The material of the shielding layer is any one of copper, copper alloy, aluminum, aluminum alloy, copper-aluminum composite material, and stainless steel.

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