Aluminum wiring terminal, wiring terminal unit and assembling method

Abstract

The invention discloses an aluminum wiring terminal, a wiring terminal unit and an assembling method, and the method comprises the steps: carrying out the laser etching of a joint surface of an aluminum conductive sheet, forming a pretreated conductive sheet with a micro-nano structure, depositing a protective coating on the joint surface, and carrying out the curing, and obtaining a conductive sheet with a protective coating. And then crimping and assembling with an insulating shell assembly to form a crimping assembly, and fixing bolts are arranged in the insulating shell assembly. Applying resonance fastening of characteristic frequency to a fixing bolt in the crimping assembly, injecting a lubricating medium in the fastening process, performing synchronous detection and verification of multi-physical field parameters on the fastening assembly, and feeding back detection data to a production control system to optimize assembly process parameters; the micro-nano structure is constructed on the joint surface of the conducting strip and the protective coating is deposited, so that the interface conductivity and oxidation resistance are remarkably improved, online detection and dynamic feedback optimization are integrated, and the consistency and reliability of the product are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of connecting terminals, and in particular to an aluminum connecting terminal, a connecting terminal unit and an assembling method. Background Art

[0002] Aluminum terminal blocks, with their excellent conductivity, significant lightweight advantages, and relatively low cost, have become key components for high-voltage, high-current connections in new energy vehicles, renewable energy power generation systems, and industrial electrical equipment. This is particularly true for inter-module connections in electric vehicle high-voltage battery packs, where absolute reliability and safety of electrical connections must be guaranteed for over 15 years, operating under conditions ranging from a wide temperature range (-40°C to 120°C), high-frequency mechanical vibration, and severe humidity. As electrical systems evolve toward higher voltage platforms and greater power densities, the long-term stability and degradation resistance of aluminum terminal connections are facing unprecedented challenges.

[0003] The mainstream assembly process for existing aluminum terminal blocks typically includes steps such as stamping and forming the conductive sheet, surface pickling and passivation or micro-arc oxidation treatment, mechanical crimping, and manual or semi-automatic torque wrench tightening of bolts. While these methods can achieve basic connection functions, they have fundamental flaws when dealing with continuous and severe vibration environments: their anti-loosening designs (such as ordinary locking washers) and static surface treatment layers cannot effectively suppress the attenuation of bolt preload caused by long-term micro-wear and stress relaxation. At the same time, the contact interface is prone to damage and accelerated oxidation of the protective layer under dynamic loads, ultimately causing a nonlinear increase in contact resistance, local overheating, and even connection failure. The existing process lacks online closed-loop monitoring and dynamic compensation mechanisms for the tightening status and interface quality, which is the core pain point that makes it difficult to ensure connection reliability under harsh working conditions.

[0004] In view of this, there is a need to solve the technical problem in the prior art that under harsh working conditions (such as high vibration), the reliability of aluminum terminal blocks is reduced due to loose bolts and deterioration of the contact interface. Summary of the Invention

[0005] The object of the present invention is to provide an aluminum terminal, a terminal unit and an assembly method to solve the above technical problems.

[0006] To achieve this object, the present invention adopts the following technical solutions: A method for assembling an aluminum terminal block, comprising: Laser etching is performed on the joint surface of the aluminum conductive sheet to form a pre-treated conductive sheet with a micro-nano structure; Depositing a protective coating on the bonding surface of the pretreated conductive sheet and curing the coating to obtain a conductive sheet with a protective coating; The conductive sheet with protective coating is crimped and assembled with an insulating shell assembly, and a fixed bolt is arranged in the insulating shell assembly, so as to form a crimped assembly. The fixed bolt in the crimped assembly is subjected to resonant fastening of a characteristic frequency, and a lubricating medium is injected during the fastening process, the fastened assembly is subjected to synchronous detection and verification of multi-physical field parameters, and detection data is fed back to a production control system to optimize assembly process parameters.

[0007] Optionally, the micro-nano structure specifically comprises: a micropore array comprising hexagonal micropores of a first diameter uniformly distributed on the bonding surface, and a gradient texture structure formed by laser etching on the pore wall of the hexagonal micropore; a flow guide groove comprising a grid flow guide path and a V-shaped groove distributed on the edge of the micropore array; a transition zone composite structure comprising a plurality of wave-shaped engagement teeth arranged within a predetermined width range of the periphery of the conductive sheet; wherein the central axis of the micropore array and the extension direction of the flow guide groove form an angle of 55°-65°.

[0008] Optionally, the grid flow guide path comprises a longitudinal groove extending along the axis of the conductive sheet, and a transverse groove staggered with the longitudinal groove at an angle of 30°-45°, and a plurality of longitudinal grooves and transverse grooves form a grid flow guide path.

[0009] Optionally, a protective coating is deposited on the bonding surface of the pretreated conductive sheet and is cured to obtain a conductive sheet with a protective coating, and the specific process is as follows: the surface of the pretreated conductive sheet with a micro-nano structure is cleaned to activate the surface energy of the bonding surface; a composite protective slurry is injected into the micropore array and the flow guide groove by a negative pressure infiltration process to form a matrix filling layer; an Al2O3-ZrO2 composite ceramic coating is uniformly deposited on the bonding surface by electrostatic rotary spraying technology, and gradient thickening spraying is performed in the grid flow guide path area; a staged curing process: first, the matrix filling layer is cured by infrared radiation, and then the composite ceramic coating is cured by ultraviolet light; based on the angle distribution of the micropore array and the flow guide groove, a laser confocal microscope is used to detect the uniformity of the coating and the micropore filling rate to obtain a conductive sheet with a protective coating.

[0010] Optionally, the Al2O3-ZrO2 composite ceramic coating is uniformly deposited on the bonding surface by electrostatic rotary spraying technology, and gradient thickening spraying is performed in the grid flow guide path area, and the specific steps are as follows: A coordinate system based on the extension direction of the guide groove is established, and the conductive sheet containing the impregnated matrix filling layer is positioned on the robotic arm of the electrostatic rotary spraying equipment; The first round of rotary spraying is carried out along the longitudinal groove direction of the gridded flow guide path: The inclination angle of the spray gun is kept parallel to the longitudinal groove axis; Apply 15kV high voltage static electricity in the intersecting area of ​​the transverse grooves to deposit the base coating; Carry out directional thickening rotary spraying for the transverse grooves: adjust the spray gun to an angle of 30°~45° with the transverse grooves; increase the slurry flow rate and superimpose 20kHz ultrasonic atomization to form a gradient thickening structure in the groove area; Based on the laser displacement sensor, the coating thickness distribution is monitored in real time and the spin spraying process parameters are dynamically adjusted until the average thickness of the gridded guide path area reaches 1.3 times that of the non-groove area.

[0011] Optionally, the insulating housing assembly specifically includes: Integrated heat dissipation structure with directionally distributed heat dissipation fins on its surface; An elastic sealing member is embedded in the joint end face of the housing; A fixing bolt is provided with a limit ring and a microchannel for injecting a lubricating medium.

[0012] Optionally, resonant tightening of a characteristic frequency is applied to the fixing bolts in the crimping assembly, and a lubricating medium is injected during the tightening process, which specifically includes the following steps: Applying an initial pre-tightening force to the crimping assembly and collecting a resonant frequency spectrum of the bolt-conductive sheet system using a vibration sensor; Based on the extraction of characteristic frequency points from the resonant frequency spectrum and the characteristics of the self-lubricating limit ring of the insulating housing assembly, the amplitude-duration parameter combination of the resonant fastening is calculated; An electromagnetic actuator is used to apply axial resonant excitation at the characteristic frequency point, and lubricating medium is injected through the microchannel inside the bolt.

[0013] Optionally, the fastening assembly is subjected to simultaneous detection and verification of multiple physical field parameters, and the detection data is fed back to a production control system to optimize assembly process parameters, specifically comprising the following steps: Real-time monitoring of dynamic detection parameters during the resonant tightening process: obtaining preload fluctuations through bolt axial strain gauges, monitoring joint surface temperature distribution with an infrared thermal imager, and measuring transient contact resistance using a four-electrode method; Construct a multi-physics field coupling model, specifically: establish an exponential decay correlation function between preload force and contact resistance, and generate a spatial mapping map of temperature gradient and medium penetration depth; The dynamic detection parameters and the spatial mapping atlas are fed back to the production control system in real time to dynamically optimize subsequent amplitude-duration parameter combinations.

[0014] The present invention further provides an aluminum terminal block, which is manufactured using the above-mentioned aluminum terminal block assembly method. The aluminum terminal block specifically comprises: The conductive sheet has a micro-nano structure formed by laser etching on its joint surface; An insulating housing assembly comprising an integrated heat dissipation structure, an elastic seal, and built-in fixing bolts, wherein the fixing bolts are provided with microchannels for injection of lubricating media and a retaining ring; The dynamic sealing interface is formed by the lubricating medium injected during the resonant tightening process penetrating into the micro-nano structure.

[0015] The present invention also provides a wiring terminal unit, comprising the aluminum wiring terminal described above.

[0016] Compared with the prior art, the present invention has the following beneficial effects: first, the joint surface of the aluminum conductive sheet is laser etched to form a micro-nano structure, and a protective coating is deposited and cured on the pre-treated surface; then, the coated conductive sheet and the insulating shell assembly with built-in fixing bolts are crimped and assembled to form a crimped assembly; then, the fixing bolts in the crimped assembly are subjected to characteristic frequency resonant tightening and lubricating medium is injected at the same time; at the same time, the assembly is subjected to synchronous detection and verification of multi-physical field parameters, and real-time data is fed back to the production control system to optimize subsequent process parameters, thereby completing the assembly process; this process significantly improves the interface conductivity and antioxidant ability by constructing a micro-nano structure on the joint surface of the conductive sheet and depositing a protective coating, and adopts crimping assembly combined with characteristic frequency resonant tightening and lubricating medium injection to effectively enhance the reliability of the mechanical connection and the anti-vibration and anti-loosening performance, integrates online detection and dynamic feedback optimization, and improves the consistency and reliability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0018] The structures, proportions, sizes, etc. depicted in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not intended to limit the conditions under which the present invention can be implemented and therefore have no substantive technical significance. Any structural modifications, changes in proportional relationships, or adjustments in size should still fall within the scope of the technical contents disclosed in the present invention without affecting the effects and objectives that can be achieved by the present invention.

[0019] Figure 1 This is a schematic diagram of a flow chart of an assembly method of an aluminum terminal block according to the first embodiment of the present invention; Figure 2 This is a second flow chart of the method for assembling the aluminum terminal block of the first embodiment; Figure 3 This is a third flow chart of the method for assembling the aluminum terminal block of the first embodiment; Figure 4 This is a partial cross-sectional schematic diagram of the aluminum terminal block of the second embodiment. DETAILED DESCRIPTION

[0020] In order to make the purpose, features, and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0021] In the description of the present invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of the present invention and simplify the description. They are not intended to indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally located component.

[0022] The technical solution of the present invention will be further described below with reference to the accompanying drawings and through specific implementation methods.

[0023] Example 1: Combine Figures 1 to 3 As shown, an embodiment of the present invention provides an assembly method of an aluminum terminal block, comprising: S1, laser etching is performed on the joint surface of the aluminum conductive sheet to form a pre-treated conductive sheet with a micro-nano structure; micro-nano structures (such as micropore arrays, diversion grooves, etc.) are constructed on the joint surface of the aluminum conductive sheet through laser etching, and the controllable etching characteristics of the metal surface by high-energy laser are used to form geometric special-shaped structures and gradient textures on a microscopic scale. By increasing the contact area and surface roughness, the interface bonding strength between the conductive sheet and the protective coating and insulating shell is improved.

[0024] S2, depositing a protective coating on the joint surface of the pretreated conductive sheet and curing it to obtain a coated conductive sheet; depositing a matrix filling layer and a composite ceramic coating in sequence on the etched joint surface, and achieving densification and strengthening of the interface protective layer through a staged curing process.

[0025] S3, crimping and assembling the coated conductive sheet and the insulating housing assembly to form a crimped assembly, wherein the insulating housing assembly has built-in fixing bolts; crimping the conductive sheet with the protective coating and the insulating housing assembly with built-in fixing bolts, utilizing the pre-tightening compression of the elastic seal and the directional arrangement of the heat dissipation structure to establish a stable electrical contact interface and heat dissipation path during the mechanical fastening process.

[0026] S4 applies characteristic frequency resonant tightening to the fixing bolts in the crimping assembly and injects lubricating medium during the tightening process. The fastening assembly is subjected to simultaneous detection and verification of multi-physical field parameters, and the detection data is fed back to the production control system to optimize the assembly process parameters.

[0027] By applying resonant excitation at a characteristic frequency to the fixing bolts, the resonance effect releases frictional resistance on the threaded mating surfaces. Combined with the continuous injection of lubricant, the stick-slip effect at the interface is reduced, achieving uniform distribution and dynamic stability of the preload force. Furthermore, through real-time monitoring and data modeling of multi-physics parameters (preload force, contact resistance, and temperature gradient), a dynamic correlation between process parameters and performance indicators is established, allowing feedback to be used to adjust the resonant amplitude, duration, and other parameter combinations.

[0028] The working principle of the present invention is as follows: first, the joint surface of the aluminum conductive sheet is laser etched to form a micro-nano structure, and a protective coating is deposited and cured on the pre-treated surface; then, the coated conductive sheet and the insulating shell assembly with built-in fixing bolts are crimped and assembled to form a crimped assembly; then, the fixing bolts in the crimped assembly are subjected to characteristic frequency resonant tightening and lubricating medium is injected at the same time; at the same time, the assembly is subjected to synchronous detection and verification of multi-physical field parameters, and real-time data is fed back to the production control system to optimize subsequent process parameters, thereby completing the assembly process; this process significantly improves the interface conductivity and antioxidant ability by constructing a micro-nano structure on the joint surface of the conductive sheet and depositing a protective coating, and adopts crimping assembly combined with characteristic frequency resonant tightening and lubricating medium injection to effectively enhance the reliability of the mechanical connection and the anti-vibration and anti-loosening performance, and integrates online detection and dynamic feedback optimization to improve the consistency and reliability of the product.

[0029] In this embodiment, it is specifically described that the micro-nano structure specifically includes: The micropore array comprises hexagonal micropores of a first diameter uniformly distributed on the joint surface, and the pore walls of the hexagonal micropores have a gradient texture structure formed by laser etching.

[0030] It's important to note that an array of evenly distributed hexagonal micropores is machined into the bonding surface of the aluminum conductive sheet. The pore walls are laser-etched to create a gradient texture (a surface with a progressively rougher surface from the pore opening to the pore bottom). The regular hexagonal arrangement maximizes surface contact area, while the gradient texture provides a stepped anchoring interface for the protective coating to penetrate. This reduces stress concentration at the edges of the hexagonal micropores, preventing microcrack propagation caused by excessive local stress during the crimping process.

[0031] The guide grooves include a grid guide path and a V-shaped groove distributed on the edge of the micropore array; The flow guide grooves consist of two parts: a gridded flow path and edge V-grooves. The gridded flow path, composed of staggered longitudinal and transverse grooves, forms a directional fluid channel, facilitating the uniform filling of the protective slurry and the diffusion and penetration of the lubricant. The edge V-grooves extend along the boundaries of the micropore array. Their sharp geometry achieves two functions: first, they guide excess coating slurry toward the V-grooves during crimping, preventing contamination of the contact surface due to overflow; second, they disperse shear stress through the inclined surfaces of the groove walls under vibration conditions, delaying fatigue crack initiation.

[0032] The transition zone composite structure includes a plurality of wavy meshing teeth arranged within a preset width range around the periphery of the conductive sheet; the wavy meshing teeth arranged within a preset width range around the periphery of the conductive sheet have geometric characteristics (such as crest / trough curvature radius, tooth height) that complement the elastic seal of the insulating shell assembly.

[0033] The central axis of the micropore array forms a 55-65° angle with the extension direction of the diversion groove, rather than being arranged orthogonally or parallel. This design achieves two major optimizations through geometric asymmetry: First, during the slurry filling stage, the groove direction forms an acute angle with the micropore axis, allowing the slurry to be continuously intercepted and adsorbed by the gradient texture of the micropore walls as it flows along the grooves, improving filling density; second, during vibration load transmission, the asymmetric angle disperses shear stress to the micropore and groove walls in different directions, preventing interfacial delamination failure caused by stress superposition.

[0034] In this embodiment, it is further explained that the gridded guide path includes longitudinal grooves extending along the axis of the conductive sheet, and transverse grooves staggered at 30° to 45° with the longitudinal grooves. Several longitudinal grooves and transverse grooves form the gridded guide path.

[0035] It should be noted that through the grid groove design with optimized directional angle, the micropore penetration ability of the slurry is enhanced during the interface protective coating filling stage, and at the same time, the dynamic dissipation of the load is achieved under vibration conditions, thereby improving the aluminum terminal interface's resistance to micro-wear and stress relaxation.

[0036] In this embodiment, it is specifically described that the specific process of step S2 is: S21, the surface of the pre-treated conductive sheet with micro-nano structure is cleaned to activate the surface energy of the bonding surface; activating the surface energy of the bonding surface through plasma cleaning or chemical oxidation treatment can significantly improve the wettability of the micropore and groove surface to the protective slurry, ensuring strong interface bonding between the filling layer and the substrate.

[0037] In S22, a negative pressure infiltration process is used to inject a composite protective slurry into the micropore array and diversion grooves, forming a matrix filling layer. The pressure differential generated by the negative pressure (vacuum environment) drives the composite protective slurry to penetrate the micropore array and diversion grooves in a directional manner. The suction effect of the negative pressure infiltration forces the slurry to fully fill the gradient texture gaps at the bottom of the micropores, forming a dense matrix filling layer, eliminating bubbles and enhancing the mechanical interlocking effect of the micropore structure.

[0038] S23 uses electrostatic spin spraying to uniformly deposit an Al2O3-ZrO2 composite ceramic coating on the joint surface. A gradient thickening spraying technique is used in the gridded flow path area. Using electrostatic spin spraying, a high-voltage electrostatic field atomizes the Al2O3-ZrO2 composite ceramic slurry into charged particles, which are then directionally deposited on the joint surface. Due to the mechanical weakness of the gridded flow path area due to the interlaced grooves, a gradient thickening spraying technique is required: a higher slurry deposition rate is applied to cover the groove intersections, creating a locally thickened structure to compensate for the protective strength in stress concentration areas. The synergistic combination of Al2O3 (high hardness) and ZrO2 (thermal shock resistance) balances the coating's wear resistance with high-temperature stability.

[0039] S24, a staged curing process: First, the matrix filling layer is cured with infrared radiation, followed by the composite ceramic coating with ultraviolet light. The matrix filling layer is cured with infrared radiation, utilizing its deep thermal effect to fully crosslink and cure the resin / metal composite slurry, ensuring the overall bonding strength between the filling layer and the microporous structure. The composite ceramic coating is cured with ultraviolet light, which rapidly polymerizes through photoinitiation to form a dense ceramic layer, avoiding thermal damage to the matrix filling layer caused by high-temperature curing. This staged curing strategy effectively alleviates the curing shrinkage stress at the interface of heterogeneous materials and improves the integrity of the protective layer.

[0040] S25, based on the angle distribution between the micropore array and the diversion groove, uses laser confocal microscopy to examine coating coverage uniformity and micropore filling rate, resulting in a conductive sheet with a protective coating. Based on the angle distribution between the micropore array and the diversion groove, laser confocal microscopy is used to scan the three-dimensional topography of the joint surface, quantitatively analyzing coating coverage uniformity (focusing on coating thickness consistency in areas where the angle varies) and micropore filling rate (determining whether the slurry completely fills the gradient texture at the bottom of the pores). This test data is directly fed back into process parameter adjustments to ensure coating quality meets protective requirements under extreme operating conditions.

[0041] In this embodiment, it is specifically explained that step S23 specifically includes the following steps: S231, establishing a coordinate system based on the extension direction of the guide groove, and positioning the conductive sheet containing the impregnated matrix filling layer on the robotic arm of the electrostatic rotary spraying equipment; A coordinate system is established based on the extension direction of the diversion grooves. The conductive sheet containing the impregnated matrix filler layer is precisely positioned on the robotic arm of the electrostatic rotary spraying equipment, ensuring that the spray gun's trajectory strictly matches the geometric distribution of the groove structure. Through the reference calibration of the coordinate system, the spray path is spatially coordinated with the preset angle (55°-65°) between the micropore array and the diversion grooves. This prevents misalignment of coating deposition caused by posture deviation during the rotary spraying process, ensuring consistent coverage and directional controllability of subsequent spraying.

[0042] S232, performing the first round of rotary spraying along the longitudinal grooves of the gridded flow guide path: the spray gun inclination angle is kept parallel to the longitudinal groove axis; 15kV high voltage static electricity is applied to the intersecting area of ​​the transverse grooves to deposit the base coating; During the first round of rotary spraying along the longitudinal grooves of the gridded flow path, the spray gun's inclination angle remains parallel to the longitudinal groove axis, aligning the slurry spray direction with the groove's orientation and reducing slurry rebound losses on the groove sidewalls. Simultaneously, a 15kV high-voltage electrostatic field is applied to the intersecting areas of the transverse grooves. The electrostatic adsorption effect forces charged slurry particles to preferentially deposit at the roots of the transverse grooves, forming a uniformly covered base coating. Through the synergistic effect of geometric orientation matching and the electrostatic field, the integrity of the protective layer at the intersection of the longitudinal and transverse grooves is strengthened, avoiding the problem of coating weakness caused by structural mutations at this location.

[0043] S233, perform directional thickening rotary spraying on the transverse grooves: adjust the spray gun to an angle of 30° to 45° with the transverse grooves; increase the slurry flow rate and superimpose 20kHz ultrasonic atomization to form a gradient thickening structure in the groove area; Adjust the spray gun to a 30° to 45° angle with the horizontal groove for directional rotary spraying. This angle range can achieve two major optimizations: Slurry penetration optimization: tilted spraying allows the slurry flow to impact the groove sidewalls in a tangential direction, enhancing the lateral wetting ability of the slurry in the transverse grooves and filling the local micro-voids that may exist in the matrix filling layer; Gradient Thickening: By increasing the slurry flow rate and superimposing 20kHz ultrasonic atomization, the slurry is broken into finer particles and its kinetic energy is increased, causing more slurry to deposit at the groove bottom and the intersection of the sidewalls, forming a gradient thickening structure that gradually thins from the groove bottom to the surface. This gradient structure effectively compensates for the bending stress concentration faced by the transverse groove under vibration loads, improving crack propagation resistance.

[0044] S234, based on the real-time monitoring of the coating thickness distribution by the laser displacement sensor, the spin spraying process parameters are dynamically adjusted until the average thickness of the gridded guide path area reaches 1.3 times that of the non-groove area.

[0045] The coating thickness distribution in the gridded flow path area is monitored in real time using a laser displacement sensor. Parameters such as the jetting speed and slurry atomization pressure are adjusted through feedback control to ensure that the average thickness in the groove area reaches 1.3 times that of the non-groove area. This proportional design takes into account two requirements: Mechanical balance: By thickening the coating in the groove area to compensate for its structural fragility, stress concentration on the interface caused by sudden thickness changes can be avoided; Functional adaptation: The non-groove area (such as the microhole array surface) needs to maintain a low thickness to maintain the surface flatness and electrical performance of the conductive sheet, while the thickening of the groove area prioritizes improving wear resistance and impact resistance.

[0046] In this embodiment, the insulating housing assembly specifically includes: The integrated heat dissipation structure features directional heat dissipation fins. These fins are designed to align with the heat transfer path after crimping the conductive sheet (e.g., the direction of heat flow at the bolt-conductive sheet interface). By optimizing fin geometry (height, spacing, and curvature), the convective heat transfer area is maximized within a limited space while minimizing airflow resistance.

[0047] The elastic seal is embedded in the joint end face of the shell; the elastic seal is made of aging-resistant silicone or fluororubber, and its cross-sectional shape forms a mechanical interlocking structure with the wavy engaging teeth of the joint end face of the shell, and is pre-compressed to a set compression ratio during crimping assembly.

[0048] The fixing bolt has a built-in limit ring and a microchannel for injecting lubricant. The limit ring is an annular protrusion (limit ring) at the end of the bolt thread. It mechanically prevents excessive screwing of the bolt, ensuring that the preload force is controlled within the elastic deformation range of the material, avoiding plastic deformation or cracking of the aluminum conductive plate caused by overloaded crimping.

[0049] In this embodiment, it is specifically explained that step S4 specifically includes the following steps: S41, applying an initial preload force to the crimping assembly, and collecting a resonant frequency spectrum of the bolt-conductive sheet system using a vibration sensor; An initial preload is applied to the crimp assembly to establish initial mechanical contact between the bolt and conductive plate. The resonant frequency spectrum in this state is collected using a vibration sensor. This resonant frequency spectrum reflects dynamic response parameters such as the bolt assembly's structural stiffness and contact interface damping characteristics, providing a benchmark for subsequent resonance parameter optimization. Combining the initial preload level with the resonant frequency spectrum allows for the calibration of the system's initial dynamic performance and the identification of potential assembly gaps or material defects.

[0050] S42, extracting characteristic frequency points based on the resonant frequency spectrum and calculating the amplitude-duration parameter combination of the resonant fastening in combination with the self-lubricating limit ring characteristics of the insulating housing assembly; Based on the resonant frequency spectrum, characteristic frequency points (such as primary or secondary resonant peaks) are selected. Combined with the friction coefficient-displacement characteristic curve of the self-lubricating stop ring of the insulating housing assembly, the amplitude (vibration displacement amplitude) and duration combination of the resonant tightening are calculated. By matching the resonant excitation frequency with the system's natural frequency, the resonant energy transfer efficiency is maximized. Furthermore, based on the dynamic lubrication capability of the self-lubricating stop ring (such as the critical sliding velocity), the amplitude threshold is adjusted to prevent thread damage caused by excessive vibration.

[0051] S43, an electromagnetic actuator is used to apply axial resonant excitation at the characteristic frequency point, and a lubricating medium is injected through the microchannel inside the bolt; An electromagnetic actuator applies axial resonant excitation at a characteristic frequency. The resonance effect amplifies the tiny displacement amplitude of the contact surface between the bolt and the conductive sheet, promoting frictional self-organization between the threaded mating surfaces (such as plastic deformation of micro-asperities), resulting in a more uniform distribution of preload force. Simultaneously, a lubricant (such as silicone-based grease containing nano-ceramic particles) is injected through microchannels within the bolt. During resonant vibration, the lubricant is directed to the contact interface via capillary action, reducing stick-slip friction and suppressing fretting wear.

[0052] S44, real-time monitoring of dynamic detection parameters during the resonant tightening process: obtaining the preload fluctuation value through the bolt axial strain gauge, monitoring the joint surface temperature distribution with an infrared thermal imager, and measuring the transient contact resistance using the four-electrode method; The pre-tightening force fluctuation amplitude and variation trend are obtained by bolt axial strain gauges, and the relaxation dynamics of the threaded pair is indirectly represented; the temperature gradient distribution of the joint surface is captured by an infrared thermal imager, and potential hot spots (friction heat generation concentration areas) are located; the four-electrode method is used to measure the transient contact resistance, and the electrical performance degradation caused by interface oxidation or coating damage is quantified. The synchronous detection of the three realizes the coupling monitoring of mechanical, thermal and electrical parameters, and provides multi-dimensional data input for subsequent modeling.

[0053] S45, a multi-physical field coupling model is constructed, specifically: an exponential decay correlation function of pre-tightening force-contact resistance is established, and a spatial mapping atlas of temperature gradient-medium penetration depth is generated; An exponential correlation function of pre-tightening force decay and contact resistance rise (such as Rc=R0e -KF , wherein Rc is the contact resistance, F is the pre-tightening force, and K is the decay coefficient) is established, which reveals the accelerating effect of pre-tightening force relaxation on electrical performance degradation; a spatial mapping atlas of temperature gradient distribution and lubricating medium penetration depth is generated, and the heat conduction path and medium diffusion law are analyzed by machine learning. The model correlates the parameters across physical domains, providing a quantitative basis for real-time feedback.

[0054] S46, the dynamic detection parameters and spatial mapping atlas are fed back to the production control system in real time, and the amplitude-time parameter combination of the subsequent is dynamically optimized.

[0055] The dynamic detection parameters and spatial mapping atlas are input into the production control system in real time, and the preset performance threshold (such as pre-tightening force fluctuation ≤5%, contact resistance increase ≤20%) is compared, and the resonance amplitude and time parameters are corrected in reverse. For example, if the contact resistance is detected to be abnormally jumped, the amplitude is automatically reduced or the resonance time is shortened to suppress the interface friction overload. This dynamic optimization mechanism forms a process closed-loop control, ensuring that the process parameters of each terminal assembly are adaptive to its actual assembly state.

[0056] Embodiment two: In combination Figure 4 with the embodiment one, the application further provides an aluminum wiring terminal, which is prepared by the assembly method of the aluminum wiring terminal of the embodiment one, and specifically comprises: a conductive sheet 10, the joint surface of which has a micro-nano structure formed by laser etching, and the micro-nano structure specifically comprises a micro-hole array, a flow guide groove and a transition zone composite structure 11; an insulating shell assembly 20, which contains an integrated heat dissipation structure, an elastic sealing element and a built-in fixing bolt 30, and the fixing bolt is provided with a micro-channel for injecting lubricating medium and a limiting ring 31; a dynamic sealing interface, which is formed by the penetration of the lubricating medium injected in the resonant fastening process in the micro-nano structure.

[0057] Embodiment three: The present invention further provides a terminal unit, characterized in that it comprises the aluminum terminal as described in the second embodiment.

[0058] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that the technical solutions described in the above embodiments can still be modified, or some of the technical features thereof can be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for assembling an aluminum terminal block, characterized in that: include: Laser etching is performed on the joint surface of the aluminum conductive sheet to form a pre-treated conductive sheet with a micro-nano structure; Depositing a protective coating on the bonding surface of the pretreated conductive sheet and curing the coating to obtain a conductive sheet with a protective coating; The conductive sheet with the protective coating is crimped and assembled with the insulating housing assembly to form a crimped assembly, wherein the insulating housing assembly has a built-in fixing bolt; Resonant tightening of a characteristic frequency is applied to the fixing bolts in the crimping assembly, and a lubricating medium is injected during the tightening process. The multi-physical field parameters of the fastening assembly are synchronously detected and verified, and the detection data is fed back to the production control system to optimize the assembly process parameters.

2. The method for assembling an aluminum terminal block according to claim 1, wherein: The micro-nano structure specifically includes: A micropore array comprising hexagonal micropores of a first diameter uniformly distributed on the bonding surface, wherein the pore walls of the hexagonal micropores have a gradient texture structure formed by laser etching; A guide groove, comprising a gridded guide path and a V-shaped groove distributed on the edge of the micropore array; The transition zone composite structure includes a plurality of wave-shaped engaging teeth arranged within a preset width range of the periphery of the conductive sheet; The central axis of the micropore array forms an angle of 55°-65° with the extension direction of the guide groove.

3. The method for assembling an aluminum terminal block according to claim 2, wherein: The gridded flow guiding path includes longitudinal grooves extending along the axis direction of the conductive sheet, and transverse grooves staggered at 30° to 45° with the longitudinal grooves. Several longitudinal grooves and transverse grooves form a gridded flow guiding path.

4. The method for assembling an aluminum terminal according to claim 3, wherein: A protective coating is deposited on the bonding surface of the pretreated conductive sheet and cured to obtain a conductive sheet with a protective coating. The specific process is as follows: Cleaning the surface of the pre-treated conductive sheet with micro-nano structure to activate the surface energy of the bonding surface; The composite protective slurry is injected into the microporous array and the diversion groove using a negative pressure infiltration process to form a matrix filling layer; An Al2O3-ZrO2 composite ceramic coating is uniformly deposited on the joint surface using electrostatic spin spraying technology, with gradient thickening spraying being implemented in the gridded flow path area. Staged curing: first, the matrix filler layer is cured with infrared radiation, and then the composite ceramic coating is cured with ultraviolet light; Based on the angle distribution between the micropore array and the guide groove, a laser confocal microscope is used to detect the coating coverage uniformity and the micropore filling rate to obtain a conductive sheet with a protective coating.

5. The method for assembling an aluminum terminal according to claim 4, wherein: The Al2O3-ZrO2 composite ceramic coating is uniformly deposited on the joint surface by electrostatic rotary spraying technology, wherein the gridded flow guide path area is subjected to gradient thickening spraying, specifically comprising the following steps: A coordinate system based on the extension direction of the guide groove is established, and the conductive sheet containing the impregnated matrix filling layer is positioned on the robotic arm of the electrostatic rotary spraying equipment; The first round of rotary spraying is carried out along the longitudinal groove direction of the gridded flow guide path: The inclination angle of the spray gun is kept parallel to the longitudinal groove axis; Apply 15kV high voltage static electricity in the intersecting area of ​​the transverse grooves to deposit the base coating; Carry out directional thickening rotary spraying for the transverse grooves: adjust the spray gun to an angle of 30°~45° with the transverse grooves; increase the slurry flow rate and superimpose 20kHz ultrasonic atomization to form a gradient thickening structure in the groove area; Based on the laser displacement sensor, the coating thickness distribution is monitored in real time and the spin spraying process parameters are dynamically adjusted until the average thickness of the gridded guide path area reaches 1.3 times that of the non-groove area.

6. The method for assembling an aluminum terminal according to claim 1, wherein: The insulating housing assembly specifically comprises: Integrated heat dissipation structure with directionally distributed heat dissipation fins on its surface; An elastic sealing member is embedded in the joint end face of the housing; A fixing bolt is provided with a limit ring and a microchannel for injecting a lubricating medium.

7. The method for assembling an aluminum terminal according to claim 1, wherein: Applying characteristic frequency resonance tightening to the fixing bolts in the crimping assembly and injecting lubricating medium during the tightening process specifically includes the following steps: Applying an initial pre-tightening force to the crimping assembly and collecting a resonant frequency spectrum of the bolt-conductive sheet system using a vibration sensor; Based on the extraction of characteristic frequency points from the resonant frequency spectrum and the characteristics of the self-lubricating limit ring of the insulating housing assembly, the amplitude-duration parameter combination of the resonant fastening is calculated; An electromagnetic actuator is used to apply axial resonant excitation at the characteristic frequency point, and lubricating medium is injected through the microchannel inside the bolt.

8. The method for assembling an aluminum terminal according to claim 7, wherein: The fastening assembly is subjected to simultaneous detection and verification of multi-physics field parameters, and the detection data is fed back to the production control system to optimize the assembly process parameters, specifically comprising the following steps: Real-time monitoring of dynamic detection parameters during the resonant tightening process: obtaining preload fluctuations through bolt axial strain gauges, monitoring joint surface temperature distribution with an infrared thermal imager, and measuring transient contact resistance using a four-electrode method; Construct a multi-physics field coupling model, specifically: establish an exponential decay correlation function between preload force and contact resistance, and generate a spatial mapping map of temperature gradient and medium penetration depth; The dynamic detection parameters and the spatial mapping atlas are fed back to the production control system in real time to dynamically optimize subsequent amplitude-duration parameter combinations.

9. An aluminum terminal block, characterized in that: The aluminum terminal block is manufactured by the assembly method of any one of claims 1 to 8, wherein the aluminum terminal block specifically comprises: The conductive sheet has a micro-nano structure formed by laser etching on its joint surface; An insulating housing assembly comprising an integrated heat dissipation structure, an elastic seal, and built-in fixing bolts, wherein the fixing bolts are provided with microchannels for injection of lubricating media and a retaining ring; The dynamic sealing interface is formed by the lubricating medium injected during the resonant tightening process penetrating into the micro-nano structure.

10. A terminal unit, characterized in that: Comprising the aluminum terminal according to claim 9.

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