Junction for copper terminal and aluminium conductor and ultrasonic welding method thereof

A technology of ultrasonic welding and copper terminals, which is applied in the field of wire harnesses, can solve the problems that the industrial preparation of copper terminals and aluminum wire joints cannot be applied, the electrical and mechanical performance requirements of the joints cannot be guaranteed, and the industrial production and application of large quantities cannot be achieved. The performance improvement of electrochemical corrosion and metal corrosion resistance, the improvement of drawing force, the effect of mechanical and electrical performance guarantee

Active Publication Date: 2017-11-10
CHANGCHUN JETTY AUTOMOTIVE PARTS CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0003] For the connection conduction of aluminum and copper, there are two technical problems that have not been resolved: 1) aluminum is an active metal, and the dense oxide film with a thickness of about 50 angstroms (1 angstrom=0.1 nanometer) is formed immediately on the surface of aluminum in dry air, making Aluminum will not oxidize further, but it also greatly reduces the conductivity of the aluminum wire
2) Copper and aluminum are different elements. The metal inertness of copper is greater than that of aluminum. The electrode potential difference between copper and aluminum is 1.9997V. After the two metals are connected and energized, an electrochemical reaction will occur, causing the aluminum wire to be gradually oxidized , reduce the mechanical strength and electrical conductivity of the aluminum wire
Significant problems with ultrasonic brazing when joi

Method used

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  • Junction for copper terminal and aluminium conductor and ultrasonic welding method thereof
  • Junction for copper terminal and aluminium conductor and ultrasonic welding method thereof
  • Junction for copper terminal and aluminium conductor and ultrasonic welding method thereof

Examples

Experimental program
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Effect test

Embodiment 1

[0067] Embodiment 1 A joint of copper terminal and aluminum wire and its ultrasonic welding method

[0068] Such as figure 1 The joint of the copper terminal and the aluminum wire is shown, the copper terminal 1 is a flat copper terminal, the copper terminal 1 includes a connecting part 11, and a functional part 12, the aluminum wire 2 includes a conductor core 21 and an insulating layer 22, and the aluminum wire It is a multi-core aluminum wire ( figure 1 A) or solid aluminum wire ( figure 1 B). The lead core of the aluminum wire 2 is connected to the connecting piece 11 of the copper terminal 1 , and an interval metal layer 3 is included between the lead core of the aluminum lead and the connecting piece of the copper terminal.

[0069] The specific welding steps of the joint are as follows:

[0070] 1) The copper terminal is plated with a spacer metal layer (nickel in this embodiment) in the welding area, and the thickness of the spacer metal layer is 8 μm.

[0071] 2)...

Embodiment 2

[0073] Embodiment 2 A joint of copper terminal and aluminum wire and its ultrasonic welding method

[0074] Such as figure 2 As shown in the joint between the copper terminal and the aluminum wire, the copper terminal 1 is an open terminal, the copper terminal 1 includes a connecting part 11, and a functional part 12, the aluminum wire 2 includes a conductor core 21 and an insulating layer 22, and the aluminum wire is Multi-core aluminum wire ( figure 2 B) or solid aluminum wire ( figure 2 C). The guide core 21 of the aluminum wire 2 is connected to the connecting piece 11 of the copper terminal 1 , and an interval metal layer 3 is also included between the guide core of the aluminum wire and the connecting piece of the copper terminal.

[0075] The specific welding steps of the joint are as follows:

[0076] 1) The copper terminal is electroplated with a spacer metal layer (zinc in this embodiment) in the welding area, and the thickness of the spacer metal layer is 5 μ...

Embodiment 3

[0080] Embodiment 3 A joint of copper terminal and aluminum wire and its ultrasonic welding method

[0081] Such as image 3 As shown in the joint between the copper terminal and the aluminum wire, the copper terminal 1 is a cylindrical terminal, the copper terminal 1 contains a connecting part 11, and a functional part 12, the aluminum wire 2 contains a conductor core 21 and an insulating layer 22, and the aluminum wire It is a multi-core aluminum wire ( image 3 A) or solid aluminum wire ( image 3 B). The guide core 21 of the aluminum wire 2 is connected to the connecting piece 11 of the copper terminal 1 , and an interval metal layer 3 is also included between the guide core of the aluminum wire and the connecting piece of the copper terminal.

[0082] The specific welding steps of the joint are as follows:

[0083] 1) The copper terminal is plated with a spacer metal layer (silver in this embodiment) in the welding area, and the thickness of the spacer metal layer is ...

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Abstract

The invention belongs to the field of a wiring hardness and specifically relates to a junction for a copper terminal and an aluminium conductor and an ultrasonic welding method thereof. In order to solve the problem that in the prior art, the electrochemical corrosion exists in the welding between the copper terminal and the aluminium conductor and the mechanical property of a welding junction is low, according to the junction and the method, a spacing metal layer is added between the copper terminal and the aluminium conductor. The spacing metal layer is fixed at a welding end of a base material in modes such as electroplating, pressure welding, electric arc spray welding or electromagnetic welding, and then the three parts: the spacing metal layer, the copper terminal and the aluminium conductor are welded together. The ultrasonic welding method provided by the invention is applicable to the welding of the copper terminal and the aluminium conductor and also applicable to the welding of various junctions. The electrochemical corrosion resulting from the potential difference of copper and an aluminium electrode can be effectively reduced. The mechanical property of the junction is improved.

Description

technical field [0001] The invention belongs to the field of wire harnesses, in particular to a joint for connecting copper terminals and aluminum wires in the wire harness and an ultrasonic welding method thereof. Background technique [0002] Copper has good electrical conductivity, thermal conductivity, and plasticity and is widely used. However, copper resources are in short supply and copper costs are high. For this reason, 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. Therefore, replacing copper with aluminum is the main trend of development at present. However, some properties of aluminum are still not as good as copper, and many components still cannot be fully used. Aluminum replaces copper, so there is joint welding between aluminum components and copper components. For example, wires made of aluminum-based mate...

Claims

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Application Information

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IPC IPC(8): H01R4/62H01R11/12H01R43/02
CPCH01R4/62H01R4/625H01R11/12H01R43/02H01R43/0207H01R4/184H01R13/03B23K20/10B23K20/004B23K20/2333B23K20/24B23K2101/32B23K2101/38B23K2103/10B23K2103/12B23K2103/18
Inventor 不公告发明人
Owner CHANGCHUN JETTY AUTOMOTIVE PARTS CORP
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