CN108630342B - flexible bus and preparation method thereof - Google Patents
flexible bus and preparation method thereof Download PDFInfo
- Publication number
- CN108630342B CN108630342B CN201710154283.9A CN201710154283A CN108630342B CN 108630342 B CN108630342 B CN 108630342B CN 201710154283 A CN201710154283 A CN 201710154283A CN 108630342 B CN108630342 B CN 108630342B
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- China
- Prior art keywords
- wires
- bending
- bending area
- parts
- wire bundle
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
- H01B13/01254—Flat-harness manufacturing
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
- H01B13/01263—Tying, wrapping, binding, lacing, strapping or sheathing harnesses
- H01B13/01281—Harness wrapping apparatus
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
- H01R11/28—End pieces consisting of a ferrule or sleeve
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
- H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
- H01R11/32—End pieces with two or more terminations
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention relates to a flexible bus and a preparation method thereof, and belongs to the technical field of power supply and distribution equipment. The flexible bus comprises a conductive main body, wherein the conductive main body is a wire bundle formed by a plurality of wires, the wire bundle comprises a bending area and fixing areas positioned on two sides of the bending area in the extending direction of the conductive main body, and parts of the wires corresponding to the fixing areas are fixed with each other. The insulated flexible bus is simple and reliable, saves the installation space, and has excellent bending and safety performance.
Description
Technical Field
the invention relates to a flexible bus and a preparation method thereof, and belongs to the technical field of power supply and distribution equipment.
Background
The power supply is an important component of the electric automobile, the power battery is an important component of a power supply system, the connection of the power battery and the connection of various electric devices in the power supply system are mainly realized through a soft bus conductor, and the soft bus is mainly used for leading out battery current and forming a complete loop through transmission among the systems. The soft bus bar used at present is mainly made of a T2 copper strip with the thickness of 0.1mm or 0.5mm and the width of not more than 30mm through blanking, overlapping, welding, punching, appearance processing and insulating treatment. The flexible connection adopting the structure has the characteristics of simple process, good reliability, low impedance, simple and quick assembly and the like. However, the conductive main body of the flexible bus is formed by laminating copper strips, the cross section of the conductive main body is generally of a rectangular structure, and three defects exist after processing and forming, namely, the twisted part is of a turnover structure, and two layers of buses after turnover cannot be completely attached, so that the thickness is increased and is more than 2 times of the thickness of the flexible bus, and a larger installation space is needed; secondly, due to the limitation of the bending process, the twisted part can be bent by only 90 degrees generally; third is most soft generating line surfaces all will wrap the insulating layer, when the design is crooked and distortion, the insulating coating is bent in the lump with soft generating line, can produce plastic deformation at the department insulating layer of bending, under on-vehicle high vibration environment, the department insulating layer of bending can produce stress fatigue and then lead to the insulation failure, unexpected short circuit probably appears, cause the incident, and when the soft generating line need be extra protection processing, need to turn over a department and stretch straight the extra inoxidizing coating of cover again, such repeated operation has probably to cause original insulating layer to break.
Disclosure of Invention
The invention aims to provide a flexible bus, which aims to solve the technical problems of large installation space and small bending angle range of the flexible bus in the prior art.
The second purpose of the invention is to provide a preparation method of the flexible bus.
In order to achieve the purpose, the technical scheme of the invention is as follows:
A soft bus comprises a conductive main body, wherein the conductive main body is a wire bundle formed by a plurality of wires, the wire bundle comprises a bending area and fixing areas positioned on two sides of the bending area in the extending direction of the conductive main body, and parts of the wires corresponding to the fixing areas are fixed with each other.
The part of the lead in the fixing area is coated with a metal belt, and the metal belt and the lead and the leads are welded and fixed with each other. So set up, guarantee that flexible generating line fixed area has sufficient intensity, and can make the district of bending keep certain bending angle.
The wires are arranged in a layered structure such that the cross-section of the wire bundle is rectangular.
The wire is provided with two layers.
The wires are in a twisted structure. So set up, can prevent that the on-vehicle environment is not hard up etc. because the tie point that the vibration caused.
Each conducting wire is of a single structure or formed by stranding a plurality of sub-conducting wires.
An insulating layer is formed outside the conductive main body through a plastic dipping process.
The two end parts of the wire bundle are wrapped with metal connecting belts, and the metal connecting belts are provided with connecting holes penetrating through the metal connecting belts and the wire bundle; the two end parts of the wire bundle are mutually fixed by the wires which are coated by the metal connecting belt.
The preparation method of the flexible bus comprises the following steps: a wire bundle formed by a plurality of wires is bent according to a required shape to form a bending area, and the parts of the wires positioned at the two sides of the bending area in the extending direction of the wire bundle are mutually fixed to keep the bending area in a bending state.
Bending is performed through shaping of a tooling die.
The flexible bus can realize connection in different directions, different planes and different heights, can be bent at any angle at the twisted position directly without folding, effectively saves connection space, is provided with the fixed areas at two sides of the bending area in the extending direction of the conductive main body, and leads in the non-fixed area are physically separated, so that the rigidity and flexibility of connection are effectively ensured, and the bending angle of the bending area is ensured to be stable and not easy to deform.
Drawings
Fig. 1 is a schematic perspective view of a flexible bus bar in embodiment 1 of the present invention;
FIG. 2 is a schematic view illustrating a shaping and bending of a tooling die in embodiment 1 of the present invention;
Fig. 3 is a schematic perspective view of a flexible bus bar in embodiment 2 of the present invention.
Detailed Description
The following further describes embodiments of the present invention with reference to the drawings.
Example 1
As shown in FIG. 1, the flexible bus bar of the present embodiment has a cross-sectional area of 70mm2. The flexible bus of the embodiment comprises a main body of the conducting wireThe conductive body is externally coated with an insulating layer 3 (the insulating layer on the right side of the flexible busbar is not shown in fig. 1), which is formed by a dip molding process. The conductive main body is a wire bundle with an upper layer structure and a lower layer structure, each layer structure of the wire bundle comprises 12 wires 6, and the wires of each layer are arranged side by side. Each wire is formed by twisting 22T 2 subconductors of red copper wires with the diameter of 0.42 mm. The wire bundle is provided with a bending region 1 and fixing regions 2 located on both sides of the bending region in the extending direction of the conductive body. The parts of the leads in the bending area are not fixed with each other, namely, the parts can move relative to each other. The part of each lead in the fixed area is wrapped by a copper strip with the thickness of 0.2mm and welded by molecular diffusion welding, and after welding, the leads and the copper strip are welded into a whole, so that the connection is firm. The bending area and the fixing area are alternately distributed, so that the bending area is guaranteed to have better rigidity and flexibility, the bending and twisting effects are achieved, and looseness of connection points, bus breakage and the like caused by vibration in the vehicle-mounted environment can be prevented. The part of each wire in the bending area is not welded so as to realize bending at any angle. The outside of bending district and the outside of fixed area all are wrapped up with insulating layer 3. The two ends of the conductive main body are connecting ends 5, the insulating layer at the connecting end 5 is scraped by a cutter, the connecting end is wrapped by a metal connecting belt, and circular bolt holes 4 which penetrate through the metal connecting belt and the wire main body are formed in the connecting end. The connecting end 5 can adopt an electroplating process to ensure that the appearance size meets the connecting and mounting requirements. The flexible bus of the embodiment is provided with two bends: a first bend 7 and a second bend 8. As shown in fig. 1, the first bend 7 is a bend toward one side in the width direction of the conductive body; the second bend 8 is a bend toward the thickness direction of the conductive body.
The preparation method of the flexible bus comprises the following steps:
The method comprises the steps of shaping and bending a wire bundle formed by a plurality of wires through a tooling die according to a bending form shown in figure 1 to form a bending area, wrapping parts of the wires positioned on two sides of the bending area in the extending direction of the wire bundle by using a copper strip, welding and fixing to enable the bending area to keep a bending state, deburring and polishing, immersing the wires into a liquid plastic-containing groove after preheating to wrap an insulating layer of the wire bundle, controlling the thickness of the insulating layer by adjusting the preheating temperature of a conductor to meet the requirements of different voltage-resistant grades, and finally cooling and solidifying. And scraping the insulating layer at the connecting end by using a blade, coating the two connecting ends of the wire bundle by using a metal connecting belt, and punching a circular bolt hole penetrating through the metal connecting belt and the wire bundle. The shaping and bending of the tooling die is shown in fig. 2, the tooling die is a pressure welding tooling and comprises an upper pressure head 9 and a lower pressure head 10, the lower pressure head is provided with a groove with a rectangular cross section matched with the size of the soft bus conductor 11, the upper pressure head is provided with a bulge matched with the groove of the lower pressure head, the bulge is only arranged on a fixed welding area of the soft bus, and the rectangular groove of the lower pressure head can realize the bending and pre-arrangement of the wires.
example 2
The present embodiment is different from embodiment 1 only in that the flexible bus bar of the present embodiment is provided with only one kind of bending, as shown by a bending 12 in fig. 3, the bending shown by the bending 12 is a twisted bending, planes of two side portions of the bending part after bending are perpendicular to each other, and extension lines of the two side portions are perpendicular to each other. The connection end of the flexible bus bar of this embodiment is provided with a kidney bolt hole 13 for passing through the metal connection band and the wire harness.
In other embodiments of the present invention, the sub-conductors may also be single copper wires.
In other embodiments of the present invention, the thickness of the copper strip can be set as desired, for example, 0.1mm or 0.5 mm.
In other embodiments of the present invention, the diameter of the copper wire can be set as desired, for example, 0.1mm or 0.6 mm.
In other embodiments of the present invention, the number of the wires can be set as required, for example, 4 or 40 wires.
In other embodiments of the present invention, the number of sub-conductors may be set as desired, for example, 7 or 100 sub-conductors.
In other embodiments of the present invention, the copper wire may be replaced by an aluminum wire, and the copper tape may be replaced by an aluminum tape.
In other embodiments of the present invention, other bending angles may be set according to specific situations, and the bending direction may also be set as a twist of other shapes according to specific situations.
In other embodiments of the present invention, an insulating sleeve may be directly sleeved on the conductive main body to serve as an insulating protection layer of the conductive main body.
In other embodiments of the present invention, the number of conductor layers may be set to one or three or more, and the cross-sectional shape of the conductor bundle may also be circular.
In other embodiments of the present invention, the fixing manner of the portion of each conducting wire in the fixing area may also be soldering, or bundling or hoop.
Claims (9)
1. A flexible bus comprises a conductive main body and is characterized in that the conductive main body is a wire bundle formed by a plurality of wires, the wire bundle comprises a bending area and fixing areas positioned on two sides of the bending area in the extending direction of the conductive main body, the parts of the wires corresponding to the fixing areas are fixed with each other, the parts of the wires positioned in the fixing areas are wrapped with metal bands, and the metal bands are welded and fixed with the wires and the wires; the parts of the leads in the bending area are not fixed with each other, namely, the parts can move relative to each other, and the outer part of the bending area and the outer part of the fixing area are coated with insulating layers.
2. The flexible busbar of claim 1, wherein said conductors are arranged in a layered configuration such that said bundle is rectangular in cross-section.
3. The flexible busbar of claim 2, wherein said wire is provided in two layers.
4. The flexible busbar of claim 1, wherein said conductors are twisted.
5. The flexible busbar of claim 1, wherein each of said conductors is of a single construction or is formed by stranding a plurality of sub-conductors.
6. The flexible busbar of claim 1, wherein the conductive body is externally formed with an insulating layer by a dip-molding process.
7. The flexible busbar according to claim 1, wherein the two end portions of the wire harness are coated with metal connecting bands, and the metal connecting bands are provided with connecting holes penetrating through the metal connecting bands and the wire harness; the two end parts of the wire bundle are mutually fixed by the wires which are coated by the metal connecting belt.
8. The method for preparing the flexible busbar according to claim 1, comprising the steps of: the method comprises the steps of bending a wire bundle formed by a plurality of wires according to a required shape to form a bending area, wrapping parts of the wires positioned on two sides of the bending area in the extending direction of the wire bundle by using a metal belt, welding and fixing the parts to each other to enable the bending area to keep a bending state, deburring and polishing, preheating, immersing in a groove containing liquid plastic, and carrying out insulation layer wrapping on the wire bundle.
9. The method for manufacturing the flexible busbar according to claim 8, wherein the bend is shaped by a tooling die.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201710154283.9A CN108630342B (en) | 2017-03-15 | 2017-03-15 | flexible bus and preparation method thereof |
| PCT/CN2017/110512 WO2018166225A1 (en) | 2017-03-15 | 2017-11-10 | Flexible bus and method for manufacturing same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201710154283.9A CN108630342B (en) | 2017-03-15 | 2017-03-15 | flexible bus and preparation method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN108630342A CN108630342A (en) | 2018-10-09 |
| CN108630342B true CN108630342B (en) | 2019-12-13 |
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ID=63522648
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201710154283.9A Active CN108630342B (en) | 2017-03-15 | 2017-03-15 | flexible bus and preparation method thereof |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN108630342B (en) |
| WO (1) | WO2018166225A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110561043B (en) * | 2019-08-30 | 2021-07-09 | 东莞市万连实业有限公司 | Dislocation welding method for flexible connection part of aluminum foil flexible connection |
| JP7358935B2 (en) * | 2019-11-21 | 2023-10-11 | 株式会社オートネットワーク技術研究所 | wiring parts |
| CN217823618U (en) * | 2022-03-14 | 2022-11-15 | 吉林省中赢高科技有限公司 | Electric energy transmission assembly and vehicle |
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| CN1988019A (en) * | 2005-12-21 | 2007-06-27 | 广明光电股份有限公司 | Soft rowed line structure |
| CN101802935A (en) * | 2007-09-18 | 2010-08-11 | 罗伯特.博世有限公司 | Flexible electrical connection |
| CN202796144U (en) * | 2012-07-23 | 2013-03-13 | 达昌电子科技(苏州)有限公司 | Flexible flat cable structure |
| CN203536589U (en) * | 2013-10-25 | 2014-04-09 | 纬创资通股份有限公司 | Assembly of flexible flat cable and circuit board |
| CN204288845U (en) * | 2014-04-01 | 2015-04-22 | 湖南鼎力电气系统有限公司 | A kind of special-shaped insulated copper bus |
| CN204793649U (en) * | 2015-07-22 | 2015-11-18 | 中骏电气（厦门）有限公司 | Transformer compartment copper bar installation strutting arrangement |
| JP2016009521A (en) * | 2014-06-20 | 2016-01-18 | 住友電気工業株式会社 | Production method of flat cable and flat cable |
| JP2016085952A (en) * | 2014-10-29 | 2016-05-19 | 京セラドキュメントソリューションズ株式会社 | Flat cable, image forming apparatus equipped with the same, and method of bending flat cable |
| CN205790441U (en) * | 2016-06-25 | 2016-12-07 | 广东思科通用电力科技有限公司 | A kind of software high-conductivity polymer flexible connection structure |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3119420B2 (en) * | 1995-02-08 | 2000-12-18 | 矢崎総業株式会社 | Pressure welding harness manufacturing apparatus and manufacturing method |
| US6220874B1 (en) * | 1998-03-26 | 2001-04-24 | Sumitomo Wiring Systems, Ltd. | Wire harness assembly |
| JP2005129317A (en) * | 2003-10-22 | 2005-05-19 | Yoshinokawa Electric Wire & Cable Co Ltd | Cable with connector, and its manufacturing method |
-
2017
- 2017-03-15 CN CN201710154283.9A patent/CN108630342B/en active Active
- 2017-11-10 WO PCT/CN2017/110512 patent/WO2018166225A1/en active Application Filing
Patent Citations (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1988019A (en) * | 2005-12-21 | 2007-06-27 | 广明光电股份有限公司 | Soft rowed line structure |
| CN101802935A (en) * | 2007-09-18 | 2010-08-11 | 罗伯特.博世有限公司 | Flexible electrical connection |
| CN202796144U (en) * | 2012-07-23 | 2013-03-13 | 达昌电子科技(苏州)有限公司 | Flexible flat cable structure |
| CN203536589U (en) * | 2013-10-25 | 2014-04-09 | 纬创资通股份有限公司 | Assembly of flexible flat cable and circuit board |
| CN204288845U (en) * | 2014-04-01 | 2015-04-22 | 湖南鼎力电气系统有限公司 | A kind of special-shaped insulated copper bus |
| JP2016009521A (en) * | 2014-06-20 | 2016-01-18 | 住友電気工業株式会社 | Production method of flat cable and flat cable |
| JP2016085952A (en) * | 2014-10-29 | 2016-05-19 | 京セラドキュメントソリューションズ株式会社 | Flat cable, image forming apparatus equipped with the same, and method of bending flat cable |
| CN204793649U (en) * | 2015-07-22 | 2015-11-18 | 中骏电气（厦门）有限公司 | Transformer compartment copper bar installation strutting arrangement |
| CN205790441U (en) * | 2016-06-25 | 2016-12-07 | 广东思科通用电力科技有限公司 | A kind of software high-conductivity polymer flexible connection structure |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2018166225A1 (en) | 2018-09-20 |
| CN108630342A (en) | 2018-10-09 |
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