Electric connection assembly and preparation method thereof

Abstract

The invention discloses an electric connection assembly and a preparation method, the electric connection assembly comprises a terminal, the terminal is provided with a connecting hole, a wire and a sleeve, the sleeve sleeves one end of the wire and is fixed with the end part of the wire in a crimping manner to form a fixed part, the fixed part is inserted into the connecting hole, and the connecting hole is connected with the sleeve; and the terminal and at least the end part of the fixed part are welded and connected in a friction stir welding manner. The method is efficient, environment-friendly, firm in connection and excellent in product performance, and meets the manufacturing requirements of light-weight wire harness products.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical connection, and more specifically, to an electrical connection component and a preparation method thereof. Background Art

[0002] At present, copper wires are basically used in wiring harnesses. With the increasing urgency of global energy conservation and environmental protection, research on lightweight wiring harnesses has become the future development direction. Because copper has high density and is expensive, copper is much heavier than aluminum per unit volume and its price is much higher, so the design of terminals needs to minimize the use of copper.

[0003] Therefore, a new type of structure is needed to solve the above problems. Summary of the invention

[0004] The object of the present invention is to provide an electrical connection assembly, comprising:

[0005] A terminal, wherein a connection hole is provided on the terminal,

[0006] A wire and a sleeve, wherein the sleeve is sleeved on one end of the wire and is crimped and fixed with the end of the wire to form a fixing portion,

[0007] The fixing portion is inserted into the connection hole, and the terminal is connected to at least an end portion of the fixing portion by friction stir welding.

[0008] Optionally, the fixing portion is loosely matched with the connecting hole.

[0009] Optionally, the cross-sectional shape of the fixing portion is a polygon, and the shape of the connecting hole is matched with the cross-sectional shape of the fixing portion.

[0010] Optionally, the connecting hole is a blind hole, and at least a portion of the bottom wall of the blind hole and the end of the fixing portion are welded and connected by friction stir welding.

[0011] Optionally, the connecting hole is a through hole, the end of the fixing portion is flush with the end surface of the connecting hole, or the end of the fixing portion is higher than the end surface of the connecting hole, and at least part of the end of the sleeve is welded to the end surface of the connecting hole by stir friction welding.

[0012] Optionally, at least part of the sleeve and the end of the wire are welded and connected by means of friction stir welding, and / or at least part of the end of the wire are welded and connected by means of friction stir welding.

[0013] Optionally, the axis of the fixing portion forms a set angle with the end surface of the connecting hole.

[0014] Optionally, the sleeve is made of aluminum or aluminum alloy.

[0015] Optionally, the terminal and the sleeve are made of different materials.

[0016] The present invention also provides a method for preparing an electrical connection assembly, comprising the electrical connection assembly as described above, comprising the following steps:

[0017] S1: Processing the aluminum tube into the sleeve, using alcohol to ultrasonically clean the sleeve to remove oil and aluminum chips, and then drying it;

[0018] S2: Put the sleeve on the end of the wire, crimp the two together to form a fixed part;

[0019] S3: placing the fixing part on the friction stir welding tooling for fixing;

[0020] S4: Place the connecting hole sleeve of the terminal at the designated position of the fixing part and fix it;

[0021] S5: Adjust the friction stir welding equipment to the welding mode, weld both the terminal and the fixing part, and remove burrs.

[0022] Optionally, when the connecting hole is a through hole, and the end of the fixing portion is higher than the end surface of the connecting hole, after step S4, the method further includes:

[0023] S4.5: Adjust the friction stir welding equipment and the milling mode to mill off the fixing part protruding from the upper surface of the terminal to ensure that it protrudes from the terminal plane by 0.1 mm;

[0024] Optionally, when the connecting hole is a blind hole, after step S3, the method further includes:

[0025] S3.5: Adjust the friction stir welding equipment, adjust the milling mode, and mill the end of the fixed part to make it smooth.

[0026] Optionally, after step S5, the method further includes:

[0027] S5.5: Adjust the friction stir welding equipment to the welding mode to weld at least part of the sleeve and the end of the wire, and / or weld at least part of the end of the wire together.

[0028] The present invention has the following technical effects:

[0029] The structure of the present invention is efficient, environmentally friendly, has a firm connection, and has excellent product performance, thus meeting the manufacturing requirements of lightweight wiring harness products.

[0030] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0032] Figure 1 It is a schematic diagram of the structure of the terminal of the present invention;

[0033] Figure 2 It is a schematic diagram of the connection structure between the wire and the sleeve of the present invention;

[0034] Figure 3 It is a schematic diagram of the structure after the wire and the sleeve are crimped together in the present invention;

[0035] Figure 4 It is a schematic diagram of the connection structure of the terminal, wire and sleeve.

[0036] The following are marked in the figure:

[0037] 1. Terminal; 2. Wire; 3. Sleeve; 4. Fixing part; 11. Connection hole. DETAILED DESCRIPTION

[0038] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0039] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0040] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0041] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0042] like Figure 1-Figure 4 The electrical connection assembly shown includes: a terminal 1, a connection hole 11 is formed on the terminal 1, a wire 2 and a sleeve 3, the sleeve 3 is sleeved on one end of the wire 2 and crimped and fixed with the end of the wire 2 to form a fixing part 4, the fixing part 4 is inserted into the connection hole 11, and the terminal 1 and at least the end of the fixing part 4 are welded and connected by stir friction welding.

[0043] The shape of the fixing portion 4 formed after crimping matches the shape of the connecting hole 11 .

[0044] Furthermore, the cross-sectional shape of the fixing portion 4 is a polygon, and can be formed by one-time crimping using a polygonal crimping die, and the shape of the connecting hole 11 is matched with the cross-sectional shape of the fixing portion 4 .

[0045] The cross-sectional shape of the fixing portion 4 is a polygon, which facilitates the mold to fix the fixing portion 4 during the friction stir welding process, thereby ensuring the stability of the welding and thus ensuring the production quality.

[0046] In a specific implementation, the fixing portion 4 and the connecting hole 11 are clearance-fitted.

[0047] The fixing part 4 is fixed with a mold, and then the connection hole 11 of the terminal 1 is put on the fixing part 4. The stirring needle starts to stir along the gap between the fixing part 4 and the terminal 1, and rotates toward the center of the fixing part 4 to stir and weld, and finally closes the needle at the center of the upper surface of the fixing part 4. After the stirring needle fully stirs the fixing part 4 and the terminal 1 and the welding is completed, the burrs on the welding surface are removed.

[0048] This structure has reliable connection performance and meets the manufacturing requirements of lightweight wiring harness products.

[0049] In one embodiment, the connection hole 11 is a blind hole, and at least a portion of the bottom wall of the blind hole and the end of the fixing portion 4 are welded and connected by friction stir welding.

[0050] In another embodiment, the connection hole 11 is a through hole, and the end of the fixing portion 4 is flush with the end surface of the connection hole 11, or the end of the fixing portion 4 is higher than the end surface of the connection hole 11. At least part of the end of the sleeve 3 is welded to the end surface of the connection hole 11 by friction stir welding.

[0051] In one embodiment, at least part of the sleeve 3 and the end of the wire 2 are welded and connected by means of friction stir welding, and at least part of the end of the wire 2 is welded and connected by means of friction stir welding.

[0052] In another embodiment, at least part of the sleeve 3 and the end of the wire 2 are welded and connected by means of friction stir welding, or at least part of the end of the wire 2 are welded and connected by means of friction stir welding.

[0053] The axis of the fixing portion 4 and the end surface of the connecting hole 11 form a set angle according to actual use conditions, which can be 30°, 60°, 90° or 120°, etc. The sleeve 3 is made of aluminum or aluminum alloy.

[0054] The terminal 1 and the sleeve 3 may be made of the same or different materials.

[0055] The present invention also provides a method for preparing an electrical connection assembly, comprising the following steps:

[0056] The present invention uses a 3mm thick terminal 1, an aluminum sleeve 3 and an 85mm 2 Take wire 2 as an example.

[0057] S1: Using a CNC lathe to process the aluminum tube into the sleeve 3, the sleeve 3 after processing is ultrasonically cleaned with alcohol to remove oil and aluminum chips, and then dried;

[0058] S2: Remove the insulation skin of the end of the wire 2, put the sleeve 3 on the end of the wire 2, and crimp the two to form a fixing part 4;

[0059] S3: placing the fixing part 4 on the friction stir welding tool for fixing;

[0060] S4: Put the connection hole 11 of the terminal 1 into the designated position of the fixing part 4 and fix it; if the connection hole 11 is a through hole, preferably, the fixing part 4 is set to protrude more than 2 mm from the surface of the terminal 1 to ensure that all the conductors of the fixing part 4 protrude from the surface of the terminal 1 and remain stationary;

[0061] S5: Adjust the friction stir welding equipment to the welding mode, weld the terminal 1 and the fixing part 4, and remove the burrs.

[0062] In one embodiment, when the connection hole 11 is a through hole, and the end of the fixing portion 4 is higher than the end surface of the connection hole 11, after step S4, the method further includes:

[0063] S4.5: Adjust the friction stir welding equipment, adjust the milling mode, and mill off the fixing portion 4 protruding from the upper surface of the terminal 1 to ensure that it protrudes 0.1 mm from the plane of the terminal 1;

[0064] In another embodiment, when the connecting hole 11 is a blind hole, after step S3, the method further includes:

[0065] S3.5: Adjust the friction stir welding equipment, adjust the milling mode, and mill the end of the fixing part 4 to make it smooth.

[0066] Optionally, after step S5, the method further includes:

[0067] S5.5: Adjust the friction stir welding equipment to the welding mode to weld at least part of the sleeve 3 and the end of the wire 2, and / or weld at least part of the ends of the wire 2 together.

[0068] In order to verify the welding strength between the fixing portion 4 and the terminal 1 after crimping, the inventors conducted experimental measurements using 10 sets of identical terminals 1, wires 2 and sleeves 3. The sleeves 3 and the ends of the wires 2 were all fully stir-friction welded to the terminals 1.

[0069] The specific test method is: use a torque of 20Nm to fix the terminal 1 of the sample on a special tooling, electrically connect the two measuring points of the digital multimeter to the measuring fixture 4 and the terminal 1 respectively, and measure the resistance value after the current of 100A stabilizes.

[0070] Then, select a suitable fixture to clamp the fixed part 4 of the terminal 1 on the universal material testing machine, and record the force value of the separation of the two at a speed of 100mm / min along the axial direction of the fixed part 4, which is the pull-out force required for the test. The contact resistance <0.02mΩ and the pull-out force >3500N are qualified.

[0071] As shown in Table 1: Contact resistance and pull-out force after welding of the fixing part 4 and the terminal 1

[0072] It can be seen from Table 1 that the mechanical properties of welding can meet the requirements. The structure of this invention is efficient and environmentally friendly, has a firm connection, and has excellent product performance, meeting the manufacturing requirements of lightweight wire harness products.

[0073] Although some specific embodiments of the present invention have been described in detail by way of example, it will be appreciated by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. An electrical connection assembly, characterized in that: include: A terminal, wherein a connection hole is provided on the terminal, A wire and a sleeve, wherein the sleeve is sleeved on one end of the wire and is crimped and fixed with the end of the wire to form a fixing portion, The fixing portion is inserted into the connection hole, and the terminal is connected to at least an end portion of the fixing portion by friction stir welding.

2. The electrical connection assembly according to claim 1, characterized in that: The fixing portion is loosely matched with the connecting hole.

3. The electrical connection assembly according to claim 1, characterized in that: The cross-sectional shape of the fixing portion is a polygon, and the shape of the connecting hole is matched with the cross-sectional shape of the fixing portion.

4. The electrical connection assembly according to claim 1, characterized in that: The connecting hole is a blind hole, and at least a portion of the bottom wall of the blind hole and the end of the fixing portion are welded and connected by friction stir welding.

5. The electrical connection assembly according to claim 1, characterized in that: The connecting hole is a through hole, the end of the fixing portion is flush with the end face of the connecting hole, or the end of the fixing portion is higher than the end face of the connecting hole, and at least part of the end of the sleeve is welded to the end face of the connecting hole by stir friction welding.

6. The electrical connection assembly according to claim 1, characterized in that: At least part of the sleeve and the end of the wire are welded and connected by means of friction stir welding, and / or at least part of the end of the wire are welded and connected by means of friction stir welding.

7. The electrical connection assembly according to claim 1, characterized in that: The axis of the fixing portion forms a set angle with the end surface of the connecting hole.

8. The electrical connection assembly according to claim 1, characterized in that: The sleeve is made of aluminum or aluminum alloy.

9. The electrical connection assembly according to claim 8, characterized in that: The terminal and the sleeve are made of different materials.

10. A method for preparing an electrical connection assembly according to claims 1 to 9, characterized in that: The steps include: S1: Processing the aluminum tube into the sleeve, using alcohol to ultrasonically clean the sleeve to remove oil and aluminum chips, and then drying it; S2: Put the sleeve on the end of the wire, crimp the two together to form a fixed part; S3: placing the fixing part on the friction stir welding tooling for fixing; S4: Place the connecting hole sleeve of the terminal at the designated position of the fixing part and fix it; S5: Adjust the friction stir welding equipment to the welding mode, weld both the terminal and the fixing part, and remove burrs.

11. The method for preparing an electrical connection assembly according to claim 10, characterized in that: When the connection hole is a through hole, and the end of the fixing portion is higher than the end surface of the connection hole, after step S4, the method further includes: S4.5: Adjust the friction stir welding equipment and the milling mode to mill off the fixed part protruding from the upper surface of the terminal to ensure that it protrudes 0.1mm from the terminal plane.

12. The method for preparing an electrical connection assembly according to claim 10, characterized in that: When the connecting hole is a blind hole, after step S3, the following step is further included S3.5: Adjust the friction stir welding equipment, adjust the milling mode, and mill the end of the fixed part to make it smooth.

13. The method for preparing an electrical connection assembly according to claim 10, characterized in that: After step S5, the following steps are also included S5.5: Adjust the friction stir welding equipment to the welding mode to weld at least part of the sleeve and the end of the wire, and / or weld at least part of the end of the wire together.

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