Method for welding an aluminum bar and aluminum bar

Abstract

This invention relates to the field of welding technology, and more particularly to a method for welding aluminum busbars and the aluminum busbar itself. The aluminum busbar welding method includes the following steps: S1: Multiple aluminum foils are stacked to form an aluminum foil assembly. S2: The sides of the non-welded soft areas of the aluminum foil assembly are stamped to form multiple stacked and extruded flange structures. S3: An upper clamp and a lower clamp jointly hold the aluminum foil assembly, with the non-welded soft areas of the aluminum foil assembly located within a clearance groove formed between the upper and lower clamps. S4: An induction welding machine applies pressure and heat to the aluminum foil assembly through the upper and lower clamps to weld it into an aluminum busbar. The aluminum busbar is made from multiple aluminum foils using the above-described aluminum busbar welding method. The non-welded soft areas of the aluminum foil assembly are connected as a single unit through the flange structures, improving the structural strength and rigidity of the non-welded soft areas of the aluminum foil assembly. This avoids the phenomenon of layer-by-layer bulging after heating during the welding process, thereby preventing cracking of single-layer aluminum foil and ensuring the welding quality of the aluminum busbar.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and in particular to a welding method for aluminum busbars and an aluminum busbar. Background Technology

[0002] Currently, aluminum busbars are manufactured by welding multiple aluminum foil sheets together. The specific shape and size of the aluminum busbar can be flexibly adjusted according to application requirements. For example... Figure 1 As shown, the aluminum foil 2' is divided into a welding area and a non-welding area based on whether welding occurs, so that the welded aluminum busbar 1' has two welded hard areas 12' and one non-welded soft area 11', with the non-welded soft area 11' located between the two welded hard areas 12'. The non-welded soft area 11' facilitates the bending process of the aluminum busbar 1' to meet the usage requirements of the aluminum busbar 1'.

[0003] like Figure 2 and Figure 3 As shown, multiple aluminum foils 2' are stacked to form an aluminum foil assembly. The aluminum foil assembly undergoes induction welding under the high temperature and pressure of a clamp (including an upper clamp 10 and a lower clamp 20). When the upper clamp 10 and lower clamp 20 jointly hold the aluminum foil assembly, a clearance groove 30 is formed, and the non-welding soft region 11' of the aluminum foil assembly is located within the clearance groove 30. During the induction welding process, the aluminum foil 2' in the non-welding soft region 11' is heated along the... Figure 3 The layers bulge in the direction indicated by the middle arrow, causing the non-welded soft area 11' to be cut by the inner wall of the relief groove 30, resulting in cracking of the single layer of aluminum foil 2 and reducing the welding yield.

[0004] Therefore, there is an urgent need for an aluminum busbar welding method and an aluminum busbar to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide an aluminum busbar welding method and an aluminum busbar to avoid cracking caused by the bulging of aluminum foil layers during the welding process, thereby improving the welding yield.

[0006] To achieve this objective, the technical solution adopted by the present invention is as follows:

[0007] A method for welding aluminum busbars includes the following steps:

[0008] S1: Multiple aluminum foils are stacked to form an aluminum foil group;

[0009] S2: Stamp the side of the non-welded soft area of ​​the aluminum foil group to form multiple stacked and extruded flange structures;

[0010] S3: The upper clamp and the lower clamp together hold the aluminum foil group, and the non-welded soft area of ​​the aluminum foil group is located in the clearance groove formed between the upper clamp and the lower clamp;

[0011] S4: The induction welding machine applies pressure and heat to the aluminum foil assembly through the upper and lower clamps to weld it into an aluminum busbar.

[0012] As a preferred embodiment, in step S1, the stacked aluminum foils are stamped into a set of aluminum foils of a predetermined shape using a stamping machine.

[0013] As a preferred embodiment, in step S2, after the cutting edge of the stamping tool is rounded, the stamping machine stamps the side of the non-welded soft area of ​​the aluminum foil group through the stamping tool.

[0014] As a preferred embodiment, stamping is performed on two opposite sides of the non-welded soft region of the aluminum foil assembly.

[0015] As a preferred embodiment, the diameter of the fillet of the stamping tool is 0.3mm to 0.5mm.

[0016] As a preferred embodiment, step S4 includes step S41: when the temperature of the upper clamp and the lower clamp reaches and stabilizes at 640°C and is maintained at pressure for 70 seconds, the upper clamp and the lower clamp are then separated to release pressure.

[0017] As a preferred embodiment, step S4 includes step S42: repeating step S41 multiple times until the aluminum busbar is welded together.

[0018] As a preferred embodiment, the aluminum busbar welding method further includes step S5: cooling the aluminum busbar to room temperature.

[0019] As a preferred embodiment, step S5 is followed by step S6: leveling the non-welded soft area of ​​the aluminum busbar.

[0020] An aluminum busbar is made by welding multiple aluminum foils using the aforementioned aluminum busbar welding method.

[0021] The beneficial effects of this invention are as follows:

[0022] The aluminum foil welding method proposed in this invention forms multiple stacked and extruded flange structures by stamping the sides of the non-welded soft area of ​​the aluminum foil assembly. This connects the non-welded soft area of ​​the aluminum foil assembly into a single unit through the flange structure, improving the structural strength and rigidity of the non-welded soft area. It avoids the phenomenon of layer-by-layer bulging after heating during the welding process, thereby preventing the cracking of single-layer aluminum foil caused by the inner wall of the clearance groove cutting the non-welded soft area, reducing the generation of scrap, and improving the welding yield.

[0023] The aluminum busbar proposed in this invention is made of multiple aluminum foils through the above-mentioned aluminum busbar welding method. The non-welded soft areas of the aluminum foil group are connected into one piece by a flange structure, which improves the structural strength and rigidity of the non-welded soft areas of the aluminum foil group. It can avoid the phenomenon of layer-by-layer bulging after heating during the welding process of the aluminum foil group, thereby avoiding the cracking problem of single-layer aluminum foil and ensuring the welding quality of the aluminum busbar. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the existing aluminum busbar structure;

[0025] Figure 2 This is a cross-sectional view of the existing aluminum foil assembly clamped between the upper and lower clamps;

[0026] Figure 3 yes Figure 2 A magnified view of a section at point A in the middle;

[0027] Figure 4 This is a flowchart of the main process of aluminum busbar welding method provided in the embodiments of the present invention;

[0028] Figure 5 This is a schematic diagram of the aluminum busbar provided in an embodiment of the present invention;

[0029] Figure 6 This is a partial cross-sectional view of the aluminum foil assembly after forming the flange structure provided in an embodiment of the present invention;

[0030] Figure 7 This is a cross-sectional view of the aluminum foil assembly clamped between the upper and lower clamps according to an embodiment of the present invention;

[0031] Figure 8 yes Figure 7 A magnified view of a section at point B in the middle;

[0032] Figure 9 This is a detailed flowchart of the aluminum busbar welding method provided in the embodiments of the present invention.

[0033] The component names and labels in the diagram are as follows:

[0034] 10. Upper clamp; 20. Lower clamp; 30. Clearance groove;

[0035] 1' Aluminum busbar; 11' Non-welded soft zone; 12' Welded hard zone; 2' Aluminum foil;

[0036] 1. Aluminum busbar; 11. Non-welded soft zone; 12. Welded hard zone; 13. Bright band; 2. Aluminum foil. Detailed Implementation

[0037] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention. Furthermore, it should be noted that, for ease of description, only the parts related to the present invention are shown in the accompanying drawings, not all of them.

[0038] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0039] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0040] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0041] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0042] During the process of induction welding multiple aluminum foils into an aluminum busbar, the aluminum foil in the non-welded soft area is heated, causing it to bulge layer by layer. This leads to the non-welded soft area being cut by the inner wall of the relief groove, resulting in cracking of the single layer of aluminum foil and reducing the welding yield.

[0043] To solve the above problems, such as Figures 4-7 As shown in the figure, this embodiment proposes a method for welding aluminum busbars, which specifically includes the following steps.

[0044] S1: Multiple aluminum foils 2 are stacked to form an aluminum foil group.

[0045] S2: The side of the non-welded soft area 11 of the stamped aluminum foil group to form multiple stacked and extruded connected flange structures.

[0046] S3: The upper clamp 10 and the lower clamp 20 together clamp the aluminum foil group, and the non-welded soft area 11 of the aluminum foil group is located in the clearance groove 30 formed between the upper clamp 10 and the lower clamp 20.

[0047] S4: The induction welding machine applies pressure and heat to the aluminum foil assembly through the upper clamp 10 and the lower clamp 20 to weld it into an aluminum busbar 1.

[0048] In this embodiment, by stamping the side of the non-welded soft area 11 of the aluminum foil assembly, multiple stacked and extruded flange structures are formed, so that the non-welded soft area 11 of the aluminum foil assembly is connected as one unit through the flange structure, which improves the structural strength and rigidity of the non-welded soft area 11 of the aluminum foil assembly. This can avoid the phenomenon of layer-by-layer bulging after heating during the welding process of the aluminum foil assembly, thereby avoiding the problem of cracking of the single layer of aluminum foil 2 caused by the non-welded soft area 11 being cut by the inner wall of the clearance groove 30, reducing the generation of scrap and improving the welding yield.

[0049] In step S1, the stacked aluminum foils 2 are stamped into a set of aluminum foils of a predetermined shape using a stamping machine. Specifically, when the aluminum foil set is placed on the worktable of the stamping machine, a specific stamping die can be installed at the punch of the stamping machine to stamp the aluminum foil set into the predetermined shape. Since the stamping machine is a mature product, its specific structure and working principle will not be described in detail here.

[0050] It should be noted that the flanging structure of aluminum foil 2 is also automatically completed by a stamping machine, improving processing efficiency. Specifically, in step S2, after the cutting edge of the stamping tool is rounded, the stamping machine stamps the side of the non-welded soft area 11 of the aluminum foil assembly through the stamping tool. In this embodiment, the diameter of the rounded corner of the stamping tool is 0.3mm to 0.5mm, so that the stamping tool forms a rounded cutting edge, thereby ensuring that the side of the non-welded soft area 11 of the aluminum foil assembly forms a flanging structure.

[0051] like Figure 6 As shown, the stamping tool along Figure 6The non-welded soft area 11 is cut downwards in the direction indicated by the middle arrow, thereby forming a downward-extending flange structure on the side of each aluminum foil 2 (the non-welded soft area 11 region). This flange is the overflow material generated after the edge of the aluminum foil 2 is cut. The outer surface of the overflow material has a high gloss. When multiple flange structures are folded and pressed together, a bright band 13 with a certain width is formed on the side of the non-welded soft area 11. The bright band 13 connects the non-welded soft areas 11 of the aluminum foil group to form a whole, improving the overall structural strength and rigidity of the non-welded soft area 11 to resist the bulging force caused by heat in the non-welded soft area 11, thereby avoiding the phenomenon of layer-by-layer bulging of the aluminum foil group after welding and heating.

[0052] It should be noted that stamping is performed on the two opposite sides of the non-welded soft area 11 of the aluminum foil group to form two bright bands 13 on both sides of the non-welded soft area 11 of the aluminum foil group, which further improves the connection strength and stability of each layer of aluminum foil 2 in the non-welded soft area 11.

[0053] like Figure 7 and Figure 8 As shown, the aluminum foil assembly forming the bright band 13 is placed between the upper clamp 10 and the lower clamp 20. Then, the upper clamp 10 and the lower clamp 20 are transferred to the induction welding machine's platform. An induction coil is arranged inside the platform, and the upper clamp 10 and the lower clamp 20 are located within the induction coil. When the induction coil is energized, it heats the upper clamp 10 and the lower clamp 20. Simultaneously, the induction welding machine applies a specified pressure value to the upper clamp 10 and the lower clamp 20, causing them to clamp the aluminum foil assembly together. The aluminum foil assembly completes induction welding under high temperature and high pressure without cracking, thus improving the welding yield.

[0054] It should be noted that induction welding machines are conventional equipment in the welding field, and the process of generating heat by energizing the induction coil is existing technology. Induction welding machines can apply pressure to the upper clamp 10 and lower clamp 20 via structures such as pressure rods; therefore, the structure and working principle of induction welding machines will not be elaborated upon here.

[0055] like Figure 9 As shown, step S4 includes step S41: when the temperature of the upper clamp 10 and the lower clamp 20 reaches and stabilizes at 640°C and is held under pressure for 70 seconds, the upper clamp 10 and the lower clamp 20 are then separated to release the pressure. Step S42: Step S41 is repeated multiple times until the aluminum busbar 1 is welded.

[0056] Specifically, after the induction welding machine heats the upper clamp 10 and lower clamp 20 to 640°C, it needs to hold the pressure for about 70 seconds. Then, the upper clamp 10 is raised to release the pressure on the aluminum foil assembly. The upper clamp 10 is lowered and re-clamps the aluminum foil assembly with the lower clamp 20. This process is repeated four times, completing four 70-second pressure holding processes, ultimately completing the induction welding of the aluminum busbar 1. This process allows the upper clamp 10 and lower clamp 20 to repeatedly separate and release pressure, thus preventing the aluminum foil assembly from sticking to the upper clamp 10 and lower clamp 20 at high temperatures, further improving the welding yield.

[0057] It should be noted that the upper clamp 10 and the lower clamp 20 in this embodiment are made of graphite, which has good thermal conductivity.

[0058] like Figure 9 As shown, the aluminum busbar welding method also includes step S5: cooling the aluminum busbar 1 to room temperature. After the aluminum busbar 1 is welded, it needs to be cooled to room temperature to facilitate the post-processing of the aluminum busbar 1 (i.e., leveling and bending operations). Specifically, the cooling of the aluminum busbar 1 can be achieved by natural cooling or air cooling, etc., which are not specifically limited here.

[0059] After the aluminum foil assembly undergoes induction welding, the non-welded soft area 11 may have poor flatness, affecting the bending and use of the aluminum busbar 1. Therefore, step S6 is included after step S5: flattening the non-welded soft area 11 of the aluminum busbar 1, so that the non-welded soft area 11 of the aluminum busbar 1 maintains good alignment with the welded hard area 12, thereby improving the quality of the aluminum busbar 1.

[0060] Specifically, the leveling process of aluminum busbar 1 can also be completed by a stamping machine. For example, a flat plate can be installed on the output shaft of the stamping machine, and the non-welded soft area 11 of aluminum busbar 1 can be patted or squeezed by the flat plate to make the non-welded soft area 11 flush with the welded hard area 12.

[0061] like Figure 5 As shown, this embodiment also proposes an aluminum busbar 1. Multiple aluminum foils 2 are made by the above-mentioned aluminum busbar welding method. Since the non-welded soft area 11 of the aluminum foil group is connected into one piece by the flange structure, the structural strength and rigidity of the non-welded soft area 11 of the aluminum foil group are improved. This can avoid the phenomenon of layer-by-layer bulging after heating during the welding process of the aluminum foil group, thereby avoiding the cracking problem of single-layer aluminum foil 2 and ensuring the welding quality of aluminum busbar 1.

[0062] The above embodiments merely illustrate the basic principles and characteristics of the present invention. The present invention is not limited to the above embodiments. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method of welding an aluminum busbar, the method comprising: Includes the following steps S1: Multiple aluminum foils (2) are stacked to form an aluminum foil group; S2: Stamp the side of the non-welded soft area (11) of the aluminum foil group to form multiple stacked and extruded flange structures; The aluminum foil group is stamped on two opposite sides of the non-welded soft area (11); S3: The upper clamp (10) and the lower clamp (20) together hold the aluminum foil group, and the non-welded soft area (11) of the aluminum foil group is located in the clearance groove (30) formed between the upper clamp (10) and the lower clamp (20); S4: The induction welding machine applies pressure and heat to the aluminum foil group through the upper clamp (10) and the lower clamp (20) to weld it into an aluminum busbar.

2. The aluminum busbar welding method according to claim 1, characterized by, In step S1, the stacked aluminum foils (2) are stamped into a set of aluminum foils of a predetermined shape using a stamping machine.

3. The aluminum busbar welding method according to claim 2, characterized by, In step S2, after the cutting edge of the stamping tool is rounded, the stamping machine stamps the side of the non-welded soft area (11) of the aluminum foil group through the stamping tool.

4. The aluminum busbar welding method according to claim 3, characterized in that, The diameter of the rounded corner of the stamping tool is 0.3mm to 0.5mm.

5. The aluminum busbar welding method according to claim 1, characterized in that, Step S4 includes step S41: when the temperature of the upper clamp (10) and the lower clamp (20) reaches and stabilizes at 640°C and is held under pressure for 70 seconds, the upper clamp (10) and the lower clamp (20) are then separated and pressure is released.

6. The aluminum busbar welding method according to claim 4, characterized in that, Step S4 includes step S42: repeating step S41 multiple times until the aluminum busbar is welded.

7. The aluminum busbar welding method according to claim 1, characterized in that, The aluminum busbar welding method further includes step S5: cooling the aluminum busbar to room temperature.

8. The aluminum busbar welding method according to claim 7, characterized in that, Step S5 is followed by step S6: leveling the non-welded soft area of ​​the aluminum busbar (11).

9. An aluminum busbar, characterized in that, The aluminum busbar is made of multiple aluminum foils (2) by the aluminum busbar welding method described in any one of claims 1 to 8.

Images