DE102009032242B4 - Method for producing a busbar - Google Patents

Abstract

Method for producing a busbar for conducting electrical currents, which consists of at least two plate-like metallic conductors (1), wherein at least one of the conductors (1) is surrounded on all sides in at least one circumferential direction by a foil-like insulator (3) and then the Ladder (1) are assembled such that the conductors (1) at least partially extend side by side and are arranged electrically isolated relative to each other, characterized in that the insulator (3) is glued and autoclaved on the conductor (1), and that the Ladder (1) with at least one recess (6) are provided.

Description

The invention relates to a method for producing a bus bar for conducting electrical currents, which consists of at least two plate-like metallic conductors, wherein at least one of the conductors is surrounded at least in some areas in at least one circumferential direction on all sides by a foil-like insulator and then the conductors are assembled in such a way that the conductors extend at least partially adjacent to each other and are arranged electrically isolated relative to each other.

Such busbars are typically referred to as busbars. Such busbars are used for distribution of electrical currents, power supply and distribution of electrical power. The applications may relate to both alternating currents and direct currents. Essential is a low-impedance current flow. Also, such busbars find applications in the power supply of mobile or stationary units.

The plate-like conductors are usually separated from a dielectric layer on each other. Also, dielectric foil-like layers are often applied in the region of the top side and the bottom side of the busbars.

As critical in the application of such bus bars are edges of the busbars and recesses, through which a contacting of components. Edges and corresponding transitions are typically potted with plastics in accordance with the prior art. In the area of cracks or crevices of such potting compounds, water or moisture may enter and result in corrosion effects that either damage the material, lead to deteriorated electrical contacts or short circuits. In extreme cases, an electrical contact to connected components can also be completely interrupted.

From the DE 19917286 A1 For example, a method for producing a busbar is already known in which at least two plate-like metallic conductors are assembled. The conductors extend partially adjacent to each other and are electrically isolated relative to each other.

From the patent application published on Mar. 4, 2010 DE 10 2008 045 650 A1 It is also already known to form a busbar by a multi-numbered juxtaposed and relative to each other electrically isolated Leister.

The object of the present invention is to improve a method of the aforementioned type such that with little effort a high-quality production of the busbars is supported.

This object is achieved in that the insulator is adhered to the conductor and autoclaved, and that the conductors are provided with at least one recess.

By enclosing the conductor in the circumferential direction with the film-like insulator, it is possible to rest edge areas of the film-like insulator on each other and to glue together directly. This can be done both in the region of edges of the plate-like conductors as well as in the range of intended breakthroughs. A casting of separate insulating layers in the region of openings and edges with insulation masses is thus no longer necessary.

A simple production is supported by the fact that the insulator is glued on the ladder and autoclaved. Alternatively, it is also possible to arrange the insulator using at least one suitable fitting and a heating press in the region of the conductor.

A simple application of the films to the conductor is achieved in that a first film is adhered to an upper side of the conductor and a second film to a lower side of the conductor and that the two films in the region of side projections and in the region of recesses glued together and in particular are autoclaved.

A typical embodiment is that an insulating layer between the two conductors is formed at least two layers.

Increased mechanical requirements can be met by arranging at least one stabilization layer between the conductors.

A connection of supply elements to the busbar is facilitated by passing through the conductor at least one recess therethrough.

According to one embodiment, it is provided that an electrically non-insulated contact point is arranged in the region of the recess.

It is also thought that the recess is formed as an isolated recess.

• 1 einen Querschnitt durch einen in einer Umfangsrichtung allseitig von einem folienartigen Isolator umschlossenen plattenartigen Leiter,
• 2 die Anordnung von zwei gemäß 1 isolierter Leiter nebeneinander,
• 3 eine teilweise Darstellung einer gegenüber 2 abgewandelten Anordnung mit zusätzlichem Tragelement zwischen den einander zugewandten Isolationsschichten,
• 4 ein Beispiel für einen räumlichen Verlauf einer Stromschiene,
• 5 eine Draufsicht auf einen Bereich einer Stromschiene mit Durchbrüchen zur Kontaktierung,
• 6 eine perspektivische teilweise Darstellung einer Stromschiene mit einer Vielzahl beim dargestellten Ausführungsbeispiel rasterartig angeordneter Durchbrüche zur Kontaktierung sowie durch die Durchbrüche hindurchragender Anschlüsse zugeordneter Bauelemente und
• 7 eine Querschnittdarstellung zur Veranschaulichung einer Durchführung des Produktionsverfahrens.

In the drawings, embodiments of the invention are shown schematically. Show it:

• 1 a cross section through a in a circumferential direction on all sides of a sheet-like insulator enclosed plate-like conductor,
• 2 the arrangement of two according to 1 isolated conductor next to each other,
• 3 a partial representation of one opposite 2 modified arrangement with additional support element between the mutually facing insulation layers,
• 4 an example of a spatial course of a busbar,
• 5 a plan view of a region of a busbar with openings for contacting,
• 6 a perspective partial view of a busbar with a plurality in the illustrated embodiment grid-like arranged apertures for contacting and through the openings protruding connections associated components and
• 7 a cross-sectional view illustrating an implementation of the production process.

1 shows a cross section through a plate-like conductor ( 1 ), which in a circumferential direction ( 2 ) of a foil-like insulator ( 3 ) is enclosed. The insulator may be formed, for example, of polyimide, polyethylene terephthalate, polyethylene naphthalate, polyamide or other suitable polymer.

The plate-like ladder ( 1 ) is made of a rod material for greater current and for lower currents from a sheet. As materials, for example, copper, brass, aluminum or alloys of the above materials can be used.

The leader ( 1 ) may be formed either entirely of the same material or provided with treated and / or coated surfaces. Corresponding surface coatings can be applied, for example, by electroplating, CVD methods, PVD methods, thermal spraying or painting.

Suitable coating materials are both metallic and non-metallic materials. By way of example, it is intended to use nickel, gold, silver, chromium, tin and lead.

The foil-like insulator ( 3 ) is preferably at least one side, often also provided on two sides with an adhesive. In particular, the use of heat-activated adhesives is intended. However, it is also conceivable to use adhesives which crosslink, for example, under the action of chemical substances or suitable radiation or unfold their adhesive properties. Furthermore, the use of non-crosslinking adhesives and the use of hot melt adhesives is intended.

Both single-component and multi-component adhesives can be used. For example, such adhesives could be based on polyacrylic, polyurethane, epoxy resins, rubber or silicone.

After an oversight of the leader ( 1 ) with the insulator ( 3 ), the arrangement is transferred, for example, into an autoclave and, under the action of a suitable pressure and a suitable temperature, a contiguous bonding takes place. In particular, in the area of an edge of the conductor ( 1 ) and in the region of openings projecting portions of the film in this case stick together in such a way that air residues between the insulator ( 3 ) and the leader ( 1 ) typically remain only to a small extent, preferably almost completely reduced. For later use of the ladder ( 1 ) can thereby be reliably prevented entry of moisture or water.

Alternatively to treatment in an autoclave, other suitable means may be used. Above all, the application of a required temperature and the achievement of a suitable pressure level are to be regarded as essential.

2 shows a cross section through a busbar ( 4 ) consisting of two insulated conductors ( 1 ) according to 1 is trained. The adjacently extending regions of the insulators ( 3 ) can be glued together, but it is also possible to realize only a support and to allow relative movements.

3 shows an embodiment in which an additional stabilization layer ( 5 ) is used. The stabilization layer ( 5 ) may be formed, for example, as a rod-like material or as a sheet or CFRP composite material and serves to increase the mechanical stability of the arrangement. In addition to the achievable improved mechanical properties, an increase in the dielectric strength and improved insulation properties can be achieved. Also in this embodiment, it is possible to either the mutually facing portions of the insulator ( 3 ) with the stabilization layer ( 5 ) or just to realize a circulation.

4 shows an example of a spatial course of a partially illustrated busbar ( 4 ). By suitable bends, the busbar ( 4 ) are adapted to the local conditions. In particular, in applications in the field of vehicle technology by using appropriate busbars ( 4 ) opened up a variety of applications.

5 shows a plan view of a busbar ( 4 ) with recesses ( 6 ). The recesses ( 6 ) serve for contacting provided connecting elements.

6 shows a partial perspective view of a busbar ( 4 ) with, for example grid-like recesses ( 6 ), through the partial contact pins ( 7 ) protrude unillustrated connection elements. Edge regions of the recesses ( 6 ) are optionally electrically isolated and allow an electrical connection between the contact pin ( 7 ) and the respective leader ( 1 ). However, it is also conceivable to provide a relatively isolated application.

In the illustrated embodiment, the contact pins ( 7 ) bolt-like external thread and a fastening can be made using nuts ( 8th ), which are screwed onto the external thread. As a result, the required fixation takes place.

Exemplary are in 6 two contact points ( 9 ) and two isolated recesses ( 10 ). The contact points ( 9 ) and the isolated recesses ( 10 ) are also in 5 located.

7 1 shows an embodiment for carrying out a production process in order to control the conductor (FIG. 1 ) with the insulator ( 3 ) to provide. The insulator ( 3 ) is already arranged in such a way that he (the conductor ( 1 ) surrounds and glued for example with this. The arrangement of the ladder ( 1 ) with the insulator arranged in the surface region ( 3 ) is within an evacuable envelope ( 11 ), which has a bag-like design. The case ( 11 ) has a connection opening ( 12 ) on.

To the connection opening ( 12 ) is connected to a vacuum device, not shown, which within the envelope ( 11 ) generates an internal pressure below one bar. Since an ambient pressure is above one bar, this application of a negative pressure causes the shell to be affected by the ambient pressure (FIG. 11 ) against the insulator ( 3 ) and thereby the insulator ( 3 ) against the leader ( 1 ) is pressed. This leads to a squeezing out of possible air pockets between the insulator ( 3 ) and the leader ( 1 ), whereby this process is optionally supported by the applied suction effect. After completion of the production process, in turn, ambient pressure in the interior ( 11 ) and it forms a sufficient distance ( 13 ) between the shell ( 11 ) and the insulator ( 3 ) to remove the finished product from the envelope ( 11 ).

As material for the shell ( 11 For example, a plastic film may be used.

In the already described production variant using a press, in particular a hot press, the use of the shell described above ( 11 ) is not required for applying a negative pressure, but can still be realized depending on the specific application requirements.

Claims (7)

Method for producing a busbar for conducting electrical currents, which consists of at least two plate-like metallic conductors (1), wherein at least one of the conductors (1) is enclosed on all sides in at least one circumferential direction by a foil-like insulator (3) and then the Ladder (1) are assembled such that the conductors (1) at least partially extend side by side and are arranged electrically isolated relative to each other, characterized in that the insulator (3) is glued and autoclaved on the conductor (1), and that the Ladder (1) with at least one recess (6) are provided. Method according to Claim 1 , characterized in that a first film-like insulator (3) on an upper side of the conductor (1) and a second film-like insulator (3) are glued to a bottom of the conductor (1) and that the films are then autoclaved together in the region of supernatants , Method according to one of Claims 1 or 2 , characterized in that the conductors (1) in the region of their mutually facing expansions of at least two insulating layers are separated from each other. Method according to one of Claims 1 to 3 , characterized in that the conductors (1) are stabilized by at least one stabilizing layer (5) arranged in a distance region of the conductors (1). Method according to one of Claims 1 to 4 , characterized in that the recess (6) is provided with an electrically non-insulated contact point (9). Method according to one of Claims 1 to 5 Characterized in that the recess (6) is provided with an electrical insulation. Method according to one of Claims 1 to 6 , characterized in that for fixing the insulator (3) in the region of the conductor (1), a heat-activatable adhesive is applied.

Images