Joint of copper terminal and aluminium conductor and resistance welding method thereof

Abstract

The invention belongs to the field of a wire harness, and particularly relates to a resistance welding structure and method between a copper terminal and an aluminium conductor. In order to solve the problems of electrochemical corrosion of welding between the copper terminal and the aluminium conductor and poor mechanical property of a welding joint in the prior art, according to the resistance welding structure and method disclosed by the invention, a separation metal layer is added between the copper terminal and the aluminium conductor; firstly, the separation metal layer is fixed at a welding end of one base metal in a mode of electroplating, pressure welding, arc spray welding or electromagnetic welding and the like; and then the separation metal layer, the copper terminal and the aluminium conductor are welded together. The resistance welding method disclosed by the invention not only is suitable for welding the copper terminal and the aluminium conductor, but also is suitable for welding of various types of joints, electrochemical corrosion caused by a potential difference of copper and aluminium electrodes can be effectively reduced, and the mechanical property of the joint is improved.

Description

technical field [0001] The invention belongs to the field of wiring harnesses, and in particular relates to a joint for connecting copper terminals and aluminum wires in the wiring harness and a resistance welding method thereof. Background technique [0002] In the field of wire harnesses, 90% of wire harnesses currently use copper wires, because copper wires have good electrical conductivity, thermal conductivity, corrosion resistance and mechanical strength. However, as the price of copper increased, people began to look for copper substitutes to reduce costs. The price of aluminum is relatively low, and it also has excellent electrical conductivity, thermal conductivity and plastic workability, and, in the case of conducting the same current, the weight of aluminum wire is about one-third of that of copper wire. Therefore, in traditional cars Under the premise of weight reduction and emission reduction, and new energy vehicles require to reduce vehicle weight, replacing...

AI Technical Summary

Problems solved by technology

However, for the combination of copper terminals and aluminum wires, the traditional crimping method cannot solve the electrochemical reaction between the aluminum wires and copper terminals over time, and cannot solve the resulting mechanical properties of the copper terminals and aluminum wire joints and electrical performance degradation

Therefore, it cannot be applied in industrial production

[0005] The existing resistance welding technology is basically based on the welding of the same metal, mostly the welding of steel sheet metal parts, while the resistance welding technology of dissimilar metals is mostly used in the resistance welding of copper and aluminum pipes in air conditioners. For example, the utility model patent CN203147094U describes the copper-aluminum tube resistance welding joint, which is to insert the copper tube shrink into the aluminum tube, and then weld the copper and aluminum together by means of resistance welding. This method is only applicable to the welding of tubes. Moreover, the problem of potential corrosion between copper and aluminum is not solved. When the welded joint contacts air and water, the aluminum tube will be corroded and the service life of the welded part will be reduced; the invention patent CN104384698A describes a multi-physics-field assisted The resistance welding method of dissimilar metal materials is to activate the metal grains and strengthen the welding effect by applying a magnetic field and ultrasonic vibration in the welding area, but the increased magnetic field and ultrasonic vibration source will significantly increase the cost and significantly reduce the stability, which is not conducive to popularization and use at all. , and did not solve the problem of potential corrosion between copper and aluminum

[0006] In summary, in the prior art, there is no welding method that can meet the mechanical and electrical performance requirements of various shapes of copper terminals and aluminum wire joints used in wire harnesses.

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