CN220605012U - Busbar, PDU module, vehicle and electric equipment - Google Patents

Abstract

The utility model relates to a busbar, a PDU module, a vehicle and electric equipment, wherein the busbar comprises a metal body and an insulating coating layer, the metal body comprises a mounting part and a connecting part connected with the mounting part, the surface of the connecting part is etched to form a plurality of nanopores, and the insulating coating layer coats the connecting part and is partially embedded into the nanopores. The utility model is suitable for various shapes of bus bars, and can effectively reduce working procedure time.

Description

Busbar, PDU module, vehicle and electric equipment

Technical Field

The utility model relates to the technical field of batteries, in particular to a busbar, a PDU module, a vehicle and electric equipment.

Background

The PDU (Power Distribution Unit) is internally provided with a plurality of high-voltage components, the high-voltage components are electrically connected through a busbar and a wire harness, and functions such as charge and discharge control, high-voltage component electrification control, circuit overload short-circuit protection, high-voltage sampling, low-voltage control and the like are provided for a high-voltage system of the new energy automobile, so that the operation of the high-voltage system is protected and monitored.

Most of the existing busbar insulation layers are formed by adopting a sleeve heat shrinkage pipe, gum dipping, powder spraying and extrusion molding process, and the busbar insulation layers prepared by adopting the powder spraying process are fragile and easy to crack and remove powder in the use process; the copper bar adopting the thermal shrinkage sleeve for insulation treatment has limited shape and structure and cannot meet the insulation requirement of the special-shaped bar.

Disclosure of Invention

Aiming at the defects of the prior art, the utility model provides a busbar, a PDU module, a vehicle and electric equipment.

The technical scheme adopted by the utility model is as follows:

the busbar comprises a metal body and an insulating coating layer, wherein the metal body comprises a mounting part and a connecting part connected with the mounting part, a plurality of nano holes are formed in the surface of the connecting part through etching, and the connecting part is coated by the insulating coating layer and partially embedded into the nano holes.

In one embodiment of the utility model, the connecting portion has at least one bending portion.

In one embodiment of the present utility model, the connecting portion has a first surface and a second surface disposed opposite to each other in a thickness direction, and the crease formed by the bending portion is located on the first surface and the second surface.

In one embodiment of the present utility model, the connecting portion further has a side surface connected to the first surface and the second surface, and the side surface is a curved surface.

In one embodiment of the present utility model, the mounting portion is provided with a through hole for electrically connecting the electrical components.

In one embodiment of the utility model, the thickness of the insulating coating is 0.1mm-2mm.

The utility model also provides a PDU module, which comprises a box body, wherein a plurality of relays and a plurality of busbar are arranged in the box body, the busbar is electrically connected with the relays, and at least one of the busbar is the busbar.

In one embodiment of the present utility model, the busbar comprises a first busbar and a second busbar, the second busbar being a busbar as described above, at least parts of the first busbar and the second busbar being staggered at intervals along a first direction, the second busbar being located between two of the first busbars.

The utility model also provides a vehicle comprising a battery and the PDU module, wherein the PDU module is electrically connected with the battery.

The utility model also provides electric equipment, which comprises a battery and the PDU module, wherein the PDU module is electrically connected with the battery.

Compared with the prior art, the technical scheme of the utility model has the following advantages:

according to the busbar, the plurality of nanopores are formed in the metal surface of the busbar, so that the plastic is uniformly embedded into the nanopores, and the plastic and the metal are integrally formed after forming. According to the utility model, the busbar is subjected to insulation treatment through nano injection molding, so that some manufacturing process defects can be avoided, and the risk of material deformation is reduced; the powder cannot be cracked and removed, so that the durability and the safety of the powder are improved; the injection molding mode is used for replacing the die extrusion molding, so that the production cost is reduced, and the production process is simplified. In addition, the insulating coating technology does not occupy space, and is applicable to various shapes of bus bars.

The busbar provided by the utility model can effectively reduce working procedure time, save cost, reduce product weight and realize light pursuit.

The PDU module of the utility model adopts the busbar, which can improve the space utilization rate in the PDU module, improve the beautiful appearance and reduce the labor cost of wiring.

The vehicle is electrically connected with the battery through the PDU module, and functions such as charge and discharge control, high-voltage component power-on control, circuit overload short-circuit protection, high-voltage sampling, low-voltage control and the like are provided for a high-voltage system of the vehicle, so that the operation of the high-voltage system is protected and monitored.

The electric equipment is electrically connected with the battery through the PDU module, so that the electric requirements of different electric equipment are met.

Drawings

In order that the utility model may be more readily understood, a more particular description of the utility model will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings.

FIG. 1 is a schematic diagram of a busbar without insulation treatment according to the present utility model.

Fig. 2 is a schematic diagram of the structure of an insulation-treated busbar according to the present utility model.

Fig. 3 is an enlarged Z-direction schematic view of the insulating coating of the busbar of the present utility model.

Fig. 4 is an enlarged schematic view of the XOY plane of the insulating coating of the busbar of the present utility model.

Fig. 5 is a schematic diagram of an insulation treatment process using nano injection molding technology in the present utility model.

Fig. 6 is a top view of a PDU module in the present utility model.

Fig. 7 is a schematic diagram of a PDU module (with a box omitted) according to the present utility model.

Fig. 8 is a side view of a PDU module (with the case omitted) in the present utility model.

Description of the specification reference numerals: 1. a case; 2. a first relay; 3. a second relay; 4. a first copper bar; 5. a second copper bar; 6. a third copper bar; 7. an insulating coating layer; 8. a through hole; 9. a metal portion; 10. a nanopore; 11. a plastic body; 12. a first surface; 13. a second surface; 14. a side surface.

Detailed Description

The present utility model will be further described with reference to the accompanying drawings and specific examples, which are not intended to be limiting, so that those skilled in the art will better understand the utility model and practice it.

The foregoing and other features, aspects and advantages of the present utility model will become more apparent from the following detailed description of the embodiments, read in conjunction with the accompanying drawings. The directional terms mentioned in the following embodiments are, for example: upper, lower, left, right, front or rear, etc., are merely references to the directions of the drawings. Thus, directional terminology is used for the purpose of illustration and is not intended to be limiting of the utility model, and furthermore, like reference numerals refer to like elements throughout the embodiments.

Example 1

Referring to fig. 1-4, a busbar includes a metal body and an insulating coating layer 7, wherein the metal body includes a mounting portion and a connecting portion connected to the mounting portion, a plurality of nanopores 10 are formed by etching the surface of the connecting portion, and the insulating coating layer 7 coats the connecting portion and is partially embedded into the nanopores 10.

According to the busbar provided by the embodiment, the plurality of nano holes are formed in the metal surface of the busbar, so that the plastic is uniformly embedded into the nano holes, and the plastic and the metal are integrally formed after forming. The busbar provided by the embodiment performs insulation treatment on the busbar through nano injection molding, so that some manufacturing process defects can be avoided, and the risk of material deformation is reduced; the powder cannot be cracked and removed, so that the durability and the safety of the powder are improved; the injection molding mode is used for replacing the die extrusion molding, so that the production cost is reduced, and the production process is simplified. In addition, the insulating coating technology does not occupy space, and is applicable to various shapes of bus bars.

Wherein, the material of the metal body is selected from one or more of copper, aluminum, copper alloy and aluminum alloy.

The connecting part is provided with at least one bending part. Further, the connecting portion has a first surface 12 and a second surface 13 disposed opposite to each other in the thickness direction, and creases formed by the bending portion are located on the first surface 12 and the second surface 13. In addition, the connecting portion further has a side surface 14 connected to the first surface 12 and the second surface 13, and the side surface is a curved surface.

The mounting portion is provided with a through hole 8 for electrically connecting the electric element.

The thickness of the insulating coating layer 7 is 0.1mm-2mm, and the material of the insulating coating layer 7 is one or more selected from polyethylene, polypropylene, polycarbonate and polystyrene.

The pore diameter of each nanopore 10 is 100nm or less, and it is understood that the surface of the metal body has a groove portion as shown in fig. 3.

As shown in fig. 5, the nano injection molding process is as follows: at this time, plastic is uniformly injected on the surface of the busbar subjected to chemical treatment, the arrow in fig. 5 indicates the direction of injecting the plastic, the plastic and the nano holes 10 are mutually embedded, the plastic is cured and formed into a plastic body 11, the plastic body 11 embedded into the nano holes 10 forms an anchor bolt effect, the metal body and the plastic body 11 can be integrally formed, the part of the surface of the busbar is uniformly coated with an insulating layer, an insulating coating 7 is formed, and the insulating layer is firmly combined with the busbar.

It should be noted that the busbar generally selects one of copper bar, aluminum bar and copper-aluminum composite bar. The electrical performance parameter index comparison of the three conductor materials of the copper bar, the aluminum bar and the copper-aluminum composite bar is shown in the following table 1, and the use reliability and service life of the three conductor materials can be seen from the comprehensive index comparison of the table 1.

Table 1 comprehensive index comparison table for copper bars, aluminum bars, copper-aluminum composite bars

The conclusion is as follows: the conductivity of the copper bus is inferior to that of silver, and the copper bus is reliable in use. Aluminum bus bars are light, low in price, and inferior to copper in conductivity, but if lap joint has the following disadvantages: (1) The aluminum surface is extremely easy to oxidize, and the contact resistance can be increased on the joint surface to generate heat and even burn. (2) The material is soft, the creep speed is high, the fastening time is long, the fastening is easy to loosen, and the heating and even burning out are caused by poor contact. For the reasons, after the aluminum busbar is electrified for a long time, the surface contact resistance is gradually increased, and the electric performance is easy to decay and even the electric conductivity is lost. Therefore, the busbar is preferably a copper busbar.

In comparison with the following prior art, the main advantages of the present utility model are as follows:

1. the working procedure is simplified: for example, the prior technology for insulating the copper bar requires secondary or multiple processing procedures, and the busbar provided by the utility model can be simplified in a primary injection molding process;

2. the working time is shortened: the original copper bar which needs a large amount of processing time for insulation treatment can be finished by one-step injection molding, and the production period is greatly shortened;

3. the mechanical properties are higher and stronger: because the plasticizer 11 and the nanopore 10 are mutually nested at the nanometer level, the bonding strength is greatly improved, and the mechanical properties are also improved by several levels.

Example two

Referring to fig. 6-8, a PDU module includes a case 1, in which a plurality of relays and a plurality of bus bars are disposed in the case 1, the bus bars are electrically connected with the relays, and at least one of the bus bars is provided for the first embodiment.

The busbar provided in the first embodiment does not occupy the internal space of the case 1, and is applicable to various shapes of busbars connected to different relays or other load components.

Specifically, the relays are two, namely a first relay 2 and a second relay 3, wherein the first relay 2 is a fast charging positive relay, the second relay 3 is a fast charging negative relay, the first copper bar 4, the second copper bar 5 and the third copper bar 6 are designed according to the current-carrying capacity of the busbar, the first copper bar 4 and the second copper bar 5 are connected with the second relay 3, the third copper bar 6 is connected with the first relay 2, a load loop is formed between the first relay 2 and the second relay 3 by the first copper bar 4, the second copper bar 5 and the third copper bar 6, the third copper bar 6 can be used as an input end, the first copper bar 4 can be used as an output end, the space in the box 1 is reasonably utilized, as shown in fig. 7, the first copper bar 4 is provided with two bending parts, the second copper bar 5 is provided with three bending parts, and the third copper bar 6 is provided with one bending part. Further, the first copper bar 4, the second copper bar 5 and the third copper bar 6 are provided with through holes 8, and the through holes 8 are used for electrically connecting electrical elements.

In addition, the box 1 may be made of the following materials according to the application scenario (for example, PDU module is installed on bus, passenger car, logistics car) and the demand: plastic, sheet metal, aluminum die casting, etc., wherein plastic housings are commonly used on BDUs (battery pack circuit breaker units).

Other electrical components such as arc extinguishers, fuses, PCB boards and the like are further arranged in the box body 1, and the design is carried out according to the electrical performance of the whole automobile.

The box body 1 is provided with a plurality of connection ports for connecting the wire harnesses, and the connection ports are divided into a whole vehicle communication port, a battery connector port, an MSD port, a four-core connector port, a two-core connector port, a selecting and matching connector port, a charging connector port and a discharging connector port, and high-voltage components are electrically connected through copper bars and the wire harnesses, so that the functions of charge and discharge control, high-voltage component power-on control, circuit overload short-circuit protection, high-voltage sampling, low-voltage control and the like are provided for a high-voltage system of a new energy automobile, and the operation of the high-voltage system is protected and monitored. The wire harness is selected to have a proper wire diameter through the current-carrying capacity, because the internal space of the box body 1 is very compact, the wire diameter of the wire harness is generally not more than 4 square, and otherwise, the bending radius of the cable is too large, so that the assembly is inconvenient; and, select the suitable terminal according to the wire diameter and both ends connecting device.

In this embodiment, as shown in fig. 6, the distance between the first copper bar 4 and the second copper bar 5 is L, so that the distance between the first copper bar 4 and the second copper bar 5 is extremely small, if the first copper bar 4 and the second copper bar 5 are accidentally overlapped together in the installation process, the heat productivity will rise, and there is a great safety hidden danger, so that any one of the copper bars must be insulated, and for saving the cost, only one of the copper bars is insulated, and no electrical connection will be generated after the first copper bar 4 and the second copper bar 5 are overlapped. In addition, since the third copper bar 6 cannot be lapped with the first copper bar 4, or else a circuit short circuit is caused, it is known that the first copper bar 4 cannot be lapped with the second copper bar 5, and the first copper bar 4 cannot be lapped with the third copper bar 6, so that the first copper bar 4 is preferably subjected to insulation treatment, and of course, the first copper bar 4, the second copper bar 5 and the third copper bar 6 can be subjected to insulation treatment, so that the manufacturing cost of the PDU is increased; as seen from the Z-axis direction, the first copper bar 4 is located between the second copper bar 5 and the third copper bar 6, and the distance between the second copper bar 5 and the third copper bar 6 is large, so that no accidental overlap generally occurs, and therefore, the first copper bar 4 is selected for insulation treatment, and a coordinate system is established with the straight line where the long side of the case 1 is located as the X-axis, the straight line where the wide side of the case 1 is located as the Y-axis, and the straight line where the height of the case 1 is located as the Z-axis, as shown in fig. 8.

In addition, because the interval L between the first copper bar 4 and the second copper bar 5 is extremely small, the reserved space is insufficient, and the insulating layer which is insulated by a dipping method is generally thicker, so that the space requirement cannot be met; the insulating layer made by the insulating treatment in a powder spraying mode is thinner and weaker, so that the problems of cracking, powder falling and the like are easy to occur, and the safety requirement cannot be met; the insulation treatment by extrusion molding and thermal shrinkage tube sleeving is very high in shape requirement on the copper bar, and cannot be applied to special-shaped bars, because the folding times and bending degree of the special-shaped bars are far greater than those of the copper bar with a common regular shape, the shape of the special-shaped bars is often determined by the set environment, the general space of the environment is limited, and the thickness of the insulation layer is also very high. In addition, the extrusion molding mode has the limitation of mold opening, and can not meet the requirement of repeated folding of the special-shaped rows; the fixability of the shape of the heat-shrinkable tube also determines that the heat-shrinkable tube can be used only for common copper bars with relatively regular shapes, and nano injection molding is further selected to perform insulation treatment on the first copper bar 4.

As can be seen from the above description, referring to fig. 2 to 5, the first copper bar 4 has an insulating coating layer 7, the insulating coating layer 7 is formed by nano injection molding, specifically, a plurality of nano holes 10 are formed on the surface of the metal portion 9 of the first copper bar 4 that needs to be subjected to insulating treatment, and the pore diameter of each nano hole 10 is less than or equal to 100nm, which is understood that the surface of the metal portion 9 has a groove portion as shown in fig. 3.

In addition, when the busbar includes a first busbar and a second busbar, the second busbar is a busbar provided in the first embodiment, at least portions of the first busbar and the second busbar are staggered along a first direction, and the second busbar is located between the two first busbars, where the first direction refers to a Z-axis direction.

As shown in fig. 5, the nano injection molding process is as follows: at this time, plastic is uniformly injected on the surface of the metal part 9 through chemical treatment, the plastic and the nano holes 10 are mutually embedded, the plastic is solidified and formed into a plastic body 11, the plastic body 11 embedded into the nano holes 10 forms an anchor bolt effect, the metal part 9 and the plastic body 11 can be integrally formed, the part of the surface of the first copper bar 4 is uniformly coated with an insulating layer, an insulating coating layer 7 is formed, and the insulating coating layer 7 is firmly combined with the copper bar.

It should be noted that, the insulating coating layer 7 of the first copper bar 4 is generally disposed in a partial area where the copper bars need to be electrically isolated, and meanwhile, in order to save cost, a portion of the first copper bar 4 needing to be insulated is controlled in an area indicated by hatching as shown in fig. 5, and the insulating layer in the area can satisfy current isolation between the first copper bar 4 and the second copper bar 5 and the third copper bar 6, and the insulating layer does not interfere with the through holes 8 of the copper bars; if the insulating layer interferes with the through hole 8, the insulating layer of the corresponding portion needs to be cut off. If the two ends of the first copper bar 4 shown in fig. 4 also need to be coated with an insulating layer, the insulating layer needs to be cut at the position corresponding to the through hole 8, that is, the insulating layer is provided with a circular groove with the same size as the through hole 8, so that the through hole 8 is exposed.

For the busbar with different shapes, the insulating coating 7 should be specified according to the practical application scene, but the following two points must be met: (1) Ensuring that the coating area of the insulating layer has no copper bars exposed outside; (2) The insulating layer of the copper bar should not interfere with the assembly holes or the positioning holes of the copper bar.

Example III

A vehicle comprising a battery and a PDU module as provided in example two, the PDU module being electrically connected to the battery.

The PDU module provided in the second embodiment is used to provide functions such as charge and discharge control, high-voltage component power-on control, circuit overload short-circuit protection, high-voltage sampling, low-voltage control and the like for the high-voltage system of the vehicle, so as to protect and monitor the operation of the high-voltage system.

The main design key point of the utility model is the structural improvement of the busbar structure, and the mechanical structure part and the electric connection part of other structures of the vehicle, such as the vehicle, are not described in detail.

Example IV

The utility model also provides electric equipment, which comprises a battery and the PDU module provided in the second embodiment, wherein the PDU module is electrically connected with the battery.

The PDU module provided in the second embodiment is adopted in the embodiment, and the electrical requirements of different electric equipment are met according to the requirements of the different electric equipment.

The main design key point of the utility model is the structural improvement of the busbar structure, and the mechanical structure part and the electric connection part of other structures of the electric equipment, such as the electric equipment, are not repeated.

In the description of the embodiments of the present utility model, it should also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "connected," and "connected" should be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present utility model will be understood in specific cases by those of ordinary skill in the art.

It is apparent that the above examples are given by way of illustration only and are not limiting of the embodiments. Other variations and modifications of the present utility model will be apparent to those of ordinary skill in the art in light of the foregoing description. It is not necessary here nor is it exhaustive of all embodiments. And obvious variations or modifications thereof are contemplated as falling within the scope of the present utility model.

Claims (10)

1. The busbar is characterized by comprising a metal body and an insulating coating layer, wherein the metal body comprises a mounting part and a connecting part connected with the mounting part, a plurality of nanopores are formed on the surface of the connecting part by etching, and the connecting part is coated by the insulating coating layer and partially embedded into the nanopores.

2. The busbar of claim 1, wherein the connecting portion has at least one bend.

3. The busbar of claim 2, wherein the connecting portion has a first surface and a second surface disposed opposite to each other in a thickness direction, and the crease formed by the bending portion is located on the first surface and the second surface.

4. A busbar according to claim 3, wherein the connecting portion further has a side surface connected to the first surface and the second surface, the side surface being curved.

5. The busbar of claim 1, wherein the mounting portion is provided with a through hole for electrically connecting the electrical components.

6. Busbar according to claim 1, wherein the thickness of the insulating coating is 0.1mm-2mm.

7. A PDU module, comprising a box, wherein a plurality of relays and a plurality of busbar are arranged in the box, the busbar is electrically connected with the relays, and at least one of the busbar is the busbar according to any one of claims 1 to 6.

8. The PDU module of claim 7, wherein the busbar comprises a first busbar and a second busbar, the second busbar being the busbar of any one of claims 1 to 6, at least portions of the first busbar and the second busbar being staggered along a first direction, the second busbar being located between two of the first busbars.

9. A vehicle comprising a battery and the PDU module of claim 7 or 8, said PDU module being electrically connected to said battery.

10. A powered device comprising a battery and the PDU module of claim 7 or 8, wherein the PDU module is electrically connected to the battery.