Simple battery core wire connecting and sealing method

Abstract

The invention discloses a battery core wire connecting and sealing technology, and aims to provide a simple battery core wire connecting and sealing method which is characterized by comprising the following steps: S1, preparation work: removing insulating layers at one ends of two sections of battery core wires to be connected, exposing conductive parts, and welding the end parts of the conductive parts of the two sections of battery core wires through welding; s2, crimping sleeve connection: respectively connecting the battery core wires at the two ends with the crimping sleeve through a crimping tool; s3, crimping protection sleeve connection: after crimping is completed, the crimping point is sleeved with the crimping protection sleeve; s4, mounting a sealing rubber sleeve: mounting the sealing rubber sleeve outside the crimping point; s5, water tightness testing: after sealing is completed, water tightness detection is carried out, and whether the sealing effect reaches the standard or not is determined; s6, external packaging: adding a layer of high-strength packaging material, including but not limited to a polyurethane material, outside the sealing rubber sleeve, and performing final packaging; the invention is suitable for the technical field of battery core wire connection sealing.

Description

Technical Field

[0001] The invention relates to a battery core wire connection and sealing technology, and more specifically, to a simple battery core wire connection and sealing method. Background Art

[0002] Normally, the simple treatment method for the connection point after the two core wires are connected is to wrap them with insulating electrical tape, etc. This simple treatment is more convenient but cannot make the connection point completely water-proof. The current water-proof connection method usually adopts the form of vulcanization packaging of the wire insulation layer. This operation is complicated and time-consuming and has requirements on the insulation layer material, and cannot cope with all situations. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention aims to provide a simple method for sealing the connection of electric core wires.

[0004] To achieve the above object, the present invention provides the following technical solution: a simple electric core wire connection and sealing method, comprising the following steps: S1. Preparation: Remove the insulation layer at one end of the two sections of the battery core wire to be connected to expose the conductive part, and weld the ends of the conductive parts of the two sections of the battery core wire by electric welding or ultrasonic welding to ensure good electrical connection between the battery core wires; S2, crimp sleeve connection: Use the crimping tool to connect the two ends of the core wire to the crimping sleeve respectively. The size of the crimping sleeve should be selected according to the diameter of the core wire to ensure good contact between the core wire and the crimping sleeve. Use the crimping tool to ensure firm crimping and good electrical connection. S3, crimping protective sleeve connection: After crimping is completed, the crimping point is put into the crimping protective cover, which can effectively prevent the crimping point from being damaged by external physical impact, and the outer surface of the crimping protective cover has an anti-slip design to enhance the sealing effect; S4. Sealing rubber sleeve installation: Install the sealing rubber sleeve to the outside of the crimping point, and use the interference fit method to squeeze and seal the insulation layer of the electric core wire and the inner surface of the rubber sleeve, which can effectively prevent water or gas leakage; S5. Water tightness test: After sealing is completed, conduct water tightness test to confirm whether the sealing effect meets the standards; S6, External packaging: In order to increase the long-term stability and durability of the connection point, a layer of high-strength packaging material, including but not limited to polyurethane material, may be added to the outside of the sealing rubber sleeve for final packaging.

[0005] The present invention is further configured as follows: in S5, the step of water tightness test comprises: S51, immerse the sealed battery core wire in water to detect whether there is water leakage at the connection point; S52, applying a water pressure of 30 MPa, and observing whether water leakage occurs at the connection point under the pressure; S53. Test the electrical performance of the connection point with an electrical test instrument to ensure its stability and the absence of short circuits; S54. Finally, judge whether the sealing of the joint meets the design requirements based on the results of electrical tests and water pressure tests. If there is no water leakage, it means that the sealed connection meets the requirements; if leakage occurs, it is necessary to recheck whether the sealing sleeve is complete and the crimping is firm.

[0006] The present invention is further configured as follows: the crimping sleeve is made of copper or copper alloy, which has good electrical conductivity and mechanical strength.

[0007] The present invention is further configured as follows: the crimping protection sleeve is made of high-strength plastic or metal material, which can effectively protect the crimping point and avoid damage caused by external force.

[0008] The present invention is further configured as follows: the sealing rubber sleeve is made of silicone rubber or fluororubber, and has excellent insulation and sealing properties.

[0009] The present invention is further configured as follows: the extrusion fit strength of the sealing rubber sleeve is 10-30N, thereby ensuring the sealing effect of the connection point.

[0010] The present invention is further configured such that the ratio of the length of the conductive portion exposed after welding the two sections of the electric core wire to the length of the sealing rubber sleeve is 1:1.2-1:1.5.

[0011] The present invention is further configured as follows: the hardness range of the sealing rubber sleeve is 30-70 Shore A to ensure that it has good sealing performance and elasticity.

[0012] The present invention is further configured as follows: the manufacturing method of the crimping sleeve comprises the following steps: S1-1, material preparation, according to the ratio requirements, mixing through an internal mixer to obtain a copper alloy, the copper content is ≥95%, the silver content is 0.5%-2%, and the zinc content is 1%-5%, and after mixing, high-temperature melting is performed to ensure that the copper alloy is uniform through precise temperature control. At the same time, a proper amount of antioxidant is prepared, and the addition amount is 0.1%-0.3% of the mass of the copper alloy. After it is cooled and formed, a high-precision CNC cutting machine is used to cut the alloy raw material according to the required crimping sleeve size; S1-2, pretreatment, use a cleaning agent to thoroughly clean the raw materials, remove surface oil and oxidation layer, and ensure that the surface of the raw materials is clean; S1-3, processing and forming, using stamping, extrusion or spinning technology to process the raw materials into the required crimping sleeve shape, and accurately process the inner and outer diameters to ensure accurate size fit; S1-4, heat treatment, heat treatment of the crimping sleeve, the temperature is controlled in the range of 200℃-400℃, and lasts for 1-2 hours to improve its mechanical strength and ensure that the crimping sleeve can withstand the pressure when the electric core wire is connected; S1-5, surface treatment, the surface of the crimping sleeve can be treated by tinning or gold plating to ensure good conductivity and corrosion resistance, and the coating thickness is controlled at 3-5μm; S1-6, quality inspection, carry out dimensional inspection on the crimping sleeve to check whether it meets the design requirements; test the hardness, conductivity and surface quality of the crimping sleeve to ensure that it meets the standard requirements; The manufacturing method of the crimping protective sleeve comprises the following steps: S2-1, material preparation, selecting a suitable polypropylene material according to the ratio requirements, selecting a toughening agent and an antioxidant according to the material type, and drying the polypropylene to remove moisture to avoid bubbles and deformation during processing; S2-2, mixing and injection molding, according to the ratio requirements, use high-precision mixing equipment to mix polypropylene, toughening agent and antioxidant in proportion, with the polypropylene content ≥80%, the toughening agent content 10%-15%, and the antioxidant content 0.5%-2%; use an injection molding machine to inject the mixed material into the mold to form a crimping protective cover; S2-3, cooling and trimming. The formed crimping protective sleeve needs to be cooled in the cooling system. The temperature is controlled within the range of 30℃-60℃. The cooling time is 5-10 minutes. After cooling, use trimming tools to remove burrs and excess parts during the forming process to ensure a smooth surface. S2-4, surface coating, spraying the surface of the crimping protective sleeve, adding UV coating or anti-ultraviolet coating to improve its wear resistance and corrosion resistance, and the thickness of the coating is controlled at 2-3μm; S2-5, quality inspection, conduct multiple tests on the crimping protective sleeve in terms of size, hardness, temperature resistance and impact resistance to ensure that it meets the design requirements; The manufacturing method of the sealing rubber sleeve comprises the following steps: S3-1, raw material preparation, selecting silicone rubber raw materials according to the ratio requirements, and drying them, with the silicone rubber content being ≥85%, the silicon dioxide content being 10%-15%, and the crosslinking agent and plasticizer content being 0.5%-3%; S3-2, mixing process, using an internal mixer to mix silicone rubber, silicon dioxide, crosslinking agent and plasticizer, during the mixing process, ensure that the raw materials are mixed evenly, the temperature is controlled at 80℃-120℃, and the mixing time is 20-30 minutes; S3-3, compression molding, putting the mixed rubber material into a mold, heating it through a compression molding machine, the compression molding temperature is 150℃-180℃, the pressure is controlled at 10-30MPa, and the heating time is 5-10 minutes to ensure that the rubber material is fully cured; S3-4, cooling and trimming, after molding, the sealing rubber sleeve is cooled to room temperature, the excess part is removed and the shape is trimmed; S3-5. Aging test: An aging test is conducted at a temperature range of 70°C-200°C for 48 hours to ensure the stability and temperature resistance of the sealing rubber sleeve in long-term use.

[0013] The beneficial effects of the present invention are: 1. Compared with the prior art, the simple battery core wire connection and sealing method of the present invention connects the conductive parts of the battery core wires by electric welding or ultrasonic welding, thereby ensuring good electrical connection between the battery core wires. In the crimping sleeve connection step, the method achieves a firm electrical connection through a crimping tool and an adapted crimping sleeve. The design of the crimping protective sleeve effectively prevents damage to the connection point by external physical impact, thereby ensuring the long-term stability of the connection point. The installation and watertightness testing of the sealing rubber sleeve can completely block water and prevent external moisture from penetrating into the battery core wire connection point, thereby ensuring the stability and durability of the battery core wire connection part in a humid environment. The overall method is simple to operate, has no special requirements for the insulating layer material, has good versatility, can adapt to the connection processing of various battery core wires, and can flexibly adjust the size and sealing performance of various components for different types of battery core wires to ensure the best sealing effect and electrical stability.

[0014] 2. In the water tightness test step of the simple battery wire connection sealing method of the present invention, the triple detection means of immersion method, pressurization method and electrical test are combined to comprehensively detect the sealing effect of the connection point. Through the test of immersion in water, it is possible to directly observe whether water leakage occurs at the connection point. Further application of a water pressure of 30MPa can simulate the use of the battery wire in an extreme environment and test the water tightness of the connection point under a high-pressure environment. The electrical test link ensures that the connection point is not only physically well sealed, but also can maintain stable electrical properties to avoid electrical short circuits or unstable current due to poor sealing. It can ensure that the battery wire connection point is completely water-blocked and meets the use requirements under various extreme conditions. Since the method is simple and effective, it can be widely used for the connection of different battery wires and does not require high skills from the operator, so it has strong versatility and adaptability.

[0015] 3. In the present invention, the crimping sleeve is made of copper or copper alloy materials. These materials have good electrical conductivity and mechanical strength, which can ensure the stability of the electrical performance of the battery core wire after connection. The good conductivity of copper or copper alloy can minimize the resistance of the connection point, improve the overall conductive efficiency of the battery core wire, and reduce the heat accumulation or unstable electrical performance caused by excessive resistance at the connection point. At the same time, copper or copper alloy has high mechanical strength and can effectively resist the action of external forces, avoiding damage to the crimping sleeve due to friction or impact during long-term use, thereby ensuring the long-term reliability of the battery core wire connection point.

[0016] 4. In the present invention, firstly, the copper alloy crimping sleeve adopts strict material ratio and precise temperature-controlled melting process to ensure the uniformity and stability of the copper alloy, thereby improving its mechanical strength and conductivity. At the same time, the heat treatment process further enhances the pressure resistance of the crimping sleeve, so that it can withstand higher pressure when the electric core wire is connected, ensuring the reliability of the connection; the surface tinning or gold plating treatment not only improves the conductivity, but also improves the corrosion resistance and prolongs the service life; secondly, the crimping protective sleeve uses polypropylene material and combines the precise ratio of toughening agent and antioxidant to ensure its superior performance in temperature resistance, impact resistance and corrosion resistance; the surface spraying UV coating improves its wear resistance and ensures its reliability in long-term use; finally, the sealing rubber sleeve adopts silicone rubber material, and after mixing, molding and other processes, it ensures its excellent sealing performance and high temperature resistance and aging resistance; after aging test, it can maintain long-term stability in high temperature environment, effectively prevent external pollutants from entering, and ensure the safety and reliability of the connection parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a structural diagram of the simple electric core wire connection seal of the present invention.

[0018] Figure 2 The present invention is a flow chart of a simple method for sealing a battery core wire.

[0019] Figure 1-2 Figure numerals: 1. crimping sleeve; 2. crimping protective sleeve; 3. sealing rubber sleeve. DETAILED DESCRIPTION

[0020] Reference Figure 1-2 The embodiment of the simple electric core wire connection and sealing method of the present invention is further described.

[0021] For ease of explanation, spatial relative terms such as "upper", "lower", "left", "right" and the like are used in the embodiments to illustrate the relationship of one element or feature shown in the figure relative to another element or feature. It should be understood that, in addition to the orientation shown in the figure, the spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figure is inverted, the element described as being "under" other elements or features will be positioned "on" other elements or features. Therefore, the exemplary term "under" can include both upper and lower orientations. The device can be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used here can be interpreted accordingly.

[0022] Furthermore, relational terms such as “first” and “second” and the like are merely used to distinguish one component from another having the same name, but do not necessarily require or imply any such actual relationship or order between these components.

[0023] Figure 1 to Figure 2 A simple electric core wire connection and sealing method is shown, comprising the following steps: S1. Preparation: Remove the insulation layer at one end of the two sections of the battery core wire to be connected to expose the conductive part, and weld the ends of the conductive parts of the two sections of the battery core wire by electric welding or ultrasonic welding to ensure good electrical connection between the battery core wires; S2, crimp sleeve 1 connection: Use a crimping tool to connect the two ends of the electric core wires to the crimping sleeve 1 respectively, and the size of the crimping sleeve 1 should be selected according to the diameter of the electric core wire to ensure good contact between the electric core wire and the crimping sleeve 1. Use a crimping tool to ensure firm crimping and good electrical connection; S3, crimping protective sleeve 2 connection: After the crimping is completed, the crimping point is put into the crimping protective sleeve 2, which can effectively prevent the crimping point from being damaged by external physical impact, and the outer surface of the crimping protective sleeve 2 has an anti-slip design to enhance the sealing effect; S4, Sealing rubber sleeve 3 installation: The sealing rubber sleeve 3 is installed to the outside of the crimping point, and the insulation layer of the electric core wire and the inner surface of the rubber sleeve are squeezed and sealed by interference fit, which can effectively prevent water or gas leakage; S5. Water tightness test: After sealing is completed, conduct water tightness test to confirm whether the sealing effect meets the standards; S6, External packaging: In order to increase the long-term stability and durability of the connection point, a layer of high-strength packaging material, including but not limited to polyurethane material, may be added to the outside of the sealing rubber sleeve 3 for final packaging; Compared with the prior art, the simplified battery core wire connection and sealing method of the present invention connects the conductive parts of the battery core wires by electric welding or ultrasonic welding, thereby ensuring good electrical connection between the battery core wires. In the method, in the crimping sleeve 1 connection step, a firm electrical connection is achieved through the crimping tool and the matching crimping sleeve 1. The design of the crimping protective sleeve 2 effectively prevents damage to the connection point by external physical impact, thereby ensuring the long-term stability of the connection point. The installation and watertightness testing of the sealing rubber sleeve 3 can completely block water and prevent external moisture from penetrating into the battery core wire connection point, thereby ensuring the stability and durability of the battery core wire connection part in a humid environment. The overall method is simple to operate, has no special requirements for the insulating layer material, has good versatility, can adapt to the connection processing of various battery core wires, and for different types of battery core wires, can flexibly adjust the size and sealing performance of various components to ensure the best sealing effect and electrical stability.

[0024] In S5, the step of water tightness test includes: S51, immerse the sealed battery core wire in water to detect whether there is water leakage at the connection point; S52, applying a water pressure of 30 MPa, and observing whether water leakage occurs at the connection point under the pressure; S53. Test the electrical performance of the connection point with an electrical test instrument to ensure its stability and the absence of short circuits; S54. Finally, according to the results of the electrical test and the water pressure test, it is determined whether the sealing of the connection point meets the design requirements. If there is no water leakage, it means that the sealing connection meets the requirements; if there is leakage, it is necessary to recheck whether the sealing sleeve is complete and whether the crimping is firm; In the water tightness test step of the present invention, the triple detection means of immersion method, pressurization method and electrical test are combined to comprehensively detect the sealing effect of the connection point. Through the test of immersion in water, it is possible to directly observe whether water leakage occurs at the connection point. Further application of a water pressure of 30MPa can simulate the use of the battery core wire in an extreme environment and test the water tightness of the connection point under a high-pressure environment. The electrical test link ensures that the connection point is not only physically well sealed, but also can maintain stable electrical properties to avoid electrical short circuits or unstable current due to poor sealing. It can ensure that the battery core wire connection point is completely water-blocked and meets the use requirements under various extreme conditions. Since the method is simple and effective, it can be generally used for the connection of different battery core wires and does not require high skills from the operator, so it has strong versatility and adaptability.

[0025] The crimping sleeve 1 is made of copper or copper alloy, which has good electrical conductivity and mechanical strength; The crimping sleeve 1 in the present invention is made of copper or copper alloy materials. These materials have good electrical conductivity and mechanical strength, and can ensure the stability of the electrical performance of the battery core wires after connection. The good electrical conductivity of copper or copper alloy can minimize the resistance of the connection point, improve the overall conductive efficiency of the battery core wires, and reduce the heat accumulation or electrical performance instability caused by excessive resistance at the connection point. At the same time, copper or copper alloy has high mechanical strength and can effectively resist the action of external forces, thereby avoiding damage to the crimping sleeve 1 due to friction or impact during long-term use, thereby ensuring the long-term reliability of the battery core wire connection point.

[0026] The crimping protection sleeve 2 is made of high-strength plastic or metal material, which can effectively protect the crimping point and avoid damage caused by external forces; It can effectively protect the crimping points and prevent external forces from damaging the connection points. The high-strength plastic or metal material has strong impact resistance and wear resistance, and can withstand long-term physical friction or collision, thereby protecting the connection parts of the electric core wires from damage and avoiding loosening of the connection points or sealing failure due to external forces. In addition, the outer surface of the crimping protective cover 2 is designed to have an anti-slip effect, which enhances its stability during installation and use, and avoids inconvenient operation or incomplete sealing due to sliding. The design of the protective cover not only improves the protection effect of the connection points, but also makes the sealing method more widely applicable.

[0027] The sealing rubber sleeve 3 is made of silicone rubber or fluororubber, and has excellent insulation and sealing properties; Silicone rubber and fluororubber can maintain stable physical properties in both high and low temperature environments, and can effectively prevent external moisture or gas from penetrating into the battery core wire connection parts, thereby avoiding electrical failures or corrosion problems caused by humid environments; Silicone rubber and fluororubber also have strong elasticity and aging resistance, and can maintain good sealing effects during long-term use, avoiding the waterproof performance of the connection point affected by aging or deformation of the sealing material; Due to their excellent insulation properties, these rubber materials can also effectively block current and avoid short circuits or battery core damage caused by electrical failure of the sealing material.

[0028] The extrusion fit strength of the sealing rubber sleeve 3 is 10-30N, ensuring the sealing effect of the connection point; This fitting strength ensures the sealing effect of the joint; through reasonable fitting strength, the sealing rubber sleeve 3 can effectively form a tight sealing contact with the insulating layer of the battery core wire to prevent the penetration of moisture or gas; at the same time, the extrusion fitting strength of the sealing rubber sleeve 3 ensures that the rubber sleeve will not be displaced or fail due to external forces during long-term use, thereby maintaining the long-term stability of the joint; through this design, the joint can effectively prevent the intrusion of moisture or gas, avoiding damage to the electrical performance of the battery core wire or failure in a humid environment.

[0029] The ratio of the length of the conductive portion exposed after welding the two sections of the electric core wire to the length of the sealing rubber sleeve 3 is 1:1.2-1:1.5; This proportion design helps to ensure that the sealing rubber sleeve 3 can fully cover the connection point to form an effective seal; through this proportion arrangement, it can be ensured that the sealing effect of the battery core wire connection point is completely water-proof and will not cause leakage due to incomplete sealing; at the same time, this proportion design can provide good sealing and protection effects without increasing excessive size and material costs, thereby enhancing the waterproof performance of the connection point; this design optimizes the sealing effect of the connection point and avoids the problem of poor sealing or waste of materials due to the sealing sleeve being too short or too long.

[0030] The hardness of the sealing rubber sleeve 3 is in the range of 30-70 Shore A to ensure that it has good sealing and elasticity; Ensure that it has appropriate elasticity and sealing performance, and the moderate hardness range enables the sealing rubber sleeve 3 to effectively prevent moisture penetration while maintaining a certain elasticity to adapt to the deformation requirements during long-term use.

[0031] The manufacturing method of the crimping sleeve 1 comprises the following steps: S1-1, material preparation, according to the ratio requirements, mixing through an internal mixer to obtain a copper alloy, the copper content is ≥95%, the silver content is 0.5%-2%, and the zinc content is 1%-5%, and after mixing, it is melted at high temperature, and the copper alloy is ensured to be uniform through precise temperature control. At the same time, an appropriate amount of antioxidant is prepared, and the addition amount is 0.1%-0.3% of the mass of the copper alloy. After it is cooled and formed, a high-precision CNC cutting machine is used to cut the alloy raw material according to the required size of the crimping sleeve 1; S1-2, pretreatment, use a cleaning agent to thoroughly clean the raw materials, remove surface oil and oxidation layer, and ensure that the surface of the raw materials is clean; S1-3, processing and forming, using stamping, extrusion or spinning technology to process the raw material into the required shape of the crimping sleeve 1, and accurately process the inner and outer diameters to ensure accurate size adaptation; S1-4, heat treatment, heat treatment is performed on the crimping sleeve 1, and the temperature is controlled within the range of 200°C-400°C for 1-2 hours to improve its mechanical strength and ensure that the crimping sleeve 1 can withstand the pressure when the electric core wire is connected; S1-5, surface treatment, the surface of the crimping sleeve 1 can be treated by tinning or gold plating to ensure good conductivity and corrosion resistance, and the coating thickness is controlled at 3-5μm; S1-6, quality inspection, carry out dimensional inspection on the crimping sleeve 1 to check whether it meets the design requirements; test the hardness, conductivity and surface quality of the crimping sleeve 1 to ensure that it meets the standard requirements; The manufacturing method of the crimping protective sleeve 2 comprises the following steps: S2-1, material preparation, selecting a suitable polypropylene material according to the ratio requirements, selecting a toughening agent and an antioxidant according to the material type, and drying the polypropylene to remove moisture to avoid bubbles and deformation during processing; S2-2, mixing and injection molding, according to the ratio requirements, use high-precision mixing equipment to mix polypropylene, toughening agent and antioxidant in proportion, with the polypropylene content ≥80%, the toughening agent content 10%-15%, and the antioxidant content 0.5%-2%; use an injection molding machine to inject the mixed material into a mold to form a crimping protective sleeve 2; S2-3, cooling and trimming. The formed crimping protective sleeve 2 needs to be cooled in a cooling system. The temperature is controlled within the range of 30°C-60°C. The cooling time is 5-10 minutes. After cooling, a trimming tool is used to remove burrs and excess parts in the forming process to ensure a smooth surface. S2-4, surface coating, spraying the surface of the crimping protective sleeve 2, adding UV coating or anti-ultraviolet coating to improve its wear resistance and corrosion resistance, and the thickness of the coating is controlled at 2-3μm; S2-5, quality inspection, conduct multiple tests on the crimping protective sleeve 2 in terms of size, hardness, temperature resistance and impact resistance to ensure that it meets the design requirements; The manufacturing method of the sealing rubber sleeve 3 comprises the following steps: S3-1, raw material preparation, selecting silicone rubber raw materials according to the ratio requirements, and drying them, with the silicone rubber content being ≥85%, the silicon dioxide content being 10%-15%, and the crosslinking agent and plasticizer content being 0.5%-3%; S3-2, mixing process, using an internal mixer to mix silicone rubber, silicon dioxide, crosslinking agent and plasticizer, during the mixing process, ensure that the raw materials are mixed evenly, the temperature is controlled at 80℃-120℃, and the mixing time is 20-30 minutes; S3-3, compression molding, putting the mixed rubber material into a mold, heating it through a compression molding machine, the compression molding temperature is 150℃-180℃, the pressure is controlled at 10-30MPa, and the heating time is 5-10 minutes to ensure that the rubber material is fully cured; S3-4, cooling and trimming, after molding, the sealing rubber sleeve 3 is cooled to room temperature, the excess part is removed and the shape is trimmed; S3-5, aging test, performing aging test, the test temperature range is 70℃-200℃, the time is 48 hours, to ensure the stability and temperature resistance of the sealing rubber sleeve 3 in long-term use; The manufacturing method of the crimping sleeve 1, the crimping protective sleeve 2 and the sealing rubber sleeve 3 significantly improves the quality and performance of the products through a series of refined process steps; First, the copper alloy crimping sleeve 1 adopts a strict material ratio and a precise temperature-controlled melting process to ensure the uniformity and stability of the copper alloy, thereby improving its mechanical strength and conductivity. At the same time, the heat treatment process further enhances the pressure resistance of the crimping sleeve 1, enabling it to withstand higher pressure when connecting the core wires, ensuring the reliability of the connection; the surface tinning or gold plating not only improves the conductivity, but also improves the corrosion resistance and prolongs the service life; Secondly, the crimping protective sleeve 2 uses polypropylene material and combines the precise ratio of toughening agent and antioxidant to ensure its superior performance in temperature resistance, impact resistance and corrosion resistance; the surface spraying UV coating improves its wear resistance and ensures its reliability in long-term use; Finally, the sealing rubber sleeve 3 is made of silicone rubber material, and after processes such as mixing and molding, its excellent sealing performance and high temperature resistance and aging resistance are ensured; after aging testing, it can maintain long-term stability in a high temperature environment, effectively prevent the entry of external pollutants, and ensure the safety and reliability of the connecting components.

[0032] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Common changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included in the protection scope of the present invention.

Claims

1. A simple electric core wire connection and sealing method, characterized in that: The following steps are involved: S1. Preparation: Remove the insulation layer at one end of the two sections of the battery core wire to be connected to expose the conductive part, and weld the ends of the conductive parts of the two sections of the battery core wire by electric welding or ultrasonic welding to ensure good electrical connection between the battery core wires; S2, crimp sleeve (1) connection: The two ends of the electric core wires are connected to the crimping sleeve (1) respectively by using a crimping tool, and the size of the crimping sleeve (1) should be selected according to the diameter of the electric core wire to ensure good contact between the electric core wire and the crimping sleeve (1). The crimping tool is used to ensure that the crimping is firm and the electrical connection is good; S3, crimping protective sleeve (2) connection: After the crimping is completed, the crimping point is inserted into the crimping protective sleeve (2), which can effectively prevent the crimping point from being damaged by external physical impact, and the outer surface of the crimping protective sleeve (2) has an anti-slip design to enhance the sealing effect; S4, Sealing rubber sleeve (3) installation: The sealing rubber sleeve (3) is installed on the outside of the crimping point, and the insulation layer of the electric core wire and the inner surface of the rubber sleeve are squeezed and sealed by interference fit, which can effectively prevent water or gas leakage; S5. Water tightness test: After sealing is completed, conduct water tightness test to confirm whether the sealing effect meets the standards; S6, External packaging: In order to increase the long-term stability and durability of the connection point, a layer of high-strength packaging material, including but not limited to polyurethane material, can be added to the outside of the sealing rubber sleeve (3) for final packaging.

2. A simple electric core wire connection and sealing method according to claim 1, characterized in that: In S5, the step of water tightness test includes: S51, immerse the sealed battery core wire in water to detect whether there is water leakage at the connection point; S52, applying a water pressure of 30 MPa, and observing whether water leakage occurs at the connection point under the pressure; S53. Test the electrical performance of the connection point with an electrical test instrument to ensure its stability and the absence of short circuits; S54. Finally, judge whether the sealing of the joint meets the design requirements based on the results of electrical tests and water pressure tests. If there is no water leakage, it means that the sealed connection meets the requirements; if leakage occurs, it is necessary to recheck whether the sealing sleeve is complete and the crimping is firm.

3. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The crimping sleeve (1) is made of copper or copper alloy and has good electrical conductivity and mechanical strength.

4. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The crimping protection sleeve (2) is made of high-strength plastic or metal material, and can effectively protect the crimping point and avoid damage caused by external forces.

5. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The sealing rubber sleeve (3) is made of silicone rubber or fluororubber and has excellent insulation and sealing properties.

6. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The extrusion fit strength of the sealing rubber sleeve (3) is 10-30N, thereby ensuring the sealing effect of the connection point.

7. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The ratio of the length of the conductive portion exposed after welding the two sections of the electric core wire to the length of the sealing rubber sleeve (3) is 1:1.2-1:1.

5.

8. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The hardness of the sealing rubber sleeve (3) is in the range of 30-70 Shore A, so as to ensure that it has good sealing performance and elasticity.

9. A simple electric core wire connection and sealing method according to claim 1, characterized in that: The manufacturing method of the crimping sleeve (1) comprises the following steps: S1-1, material preparation, according to the ratio requirements, mixing through an internal mixer to obtain a copper alloy, the copper content is ≥95%, the silver content is 0.5%-2%, and the zinc content is 1%-5%, and after mixing, it is melted at high temperature, and the copper alloy is ensured to be uniform through precise temperature control. At the same time, a proper amount of antioxidant is prepared, and the addition amount is 0.1%-0.3% of the mass of the copper alloy. After it is cooled and formed, a high-precision CNC cutting machine is used to cut the alloy raw material according to the required size of the crimping sleeve (1); S1-2, pretreatment, use a cleaning agent to thoroughly clean the raw materials, remove surface oil and oxidation layer, and ensure that the surface of the raw materials is clean; S1-3, processing and forming, using stamping, extrusion or spinning technology to process the raw material into the required shape of the crimping sleeve (1), and accurately process the inner and outer diameters to ensure accurate size fit; S1-4, heat treatment, heat treatment is performed on the crimping sleeve (1), the temperature is controlled within the range of 200°C-400°C, and the duration is 1-2 hours, so as to improve its mechanical strength and ensure that the crimping sleeve (1) can withstand the pressure when the electric core wire is connected; S1-5, surface treatment, the surface of the crimping sleeve (1) can be treated by tinning or gold plating to ensure good conductivity and corrosion resistance, and the thickness of the coating is controlled at 3-5 μm; S1-6, quality inspection, carry out dimensional inspection on the crimping sleeve (1) to check whether it meets the design requirements; test the hardness, conductivity and surface quality of the crimping sleeve (1) to ensure that it meets the standard requirements; The manufacturing method of the crimping protective sleeve (2) comprises the following steps: S2-1, material preparation, selecting a suitable polypropylene material according to the ratio requirements, selecting a toughening agent and an antioxidant according to the material type, and drying the polypropylene to remove moisture to avoid bubbles and deformation during processing; S2-2, mixing and injection molding, according to the ratio requirements, using high-precision mixing equipment, polypropylene, toughening agent and antioxidant are mixed in proportion, the polypropylene content is ≥80%, the toughening agent content is 10%-15%, and the antioxidant content is 0.5%-2%; using an injection molding machine to inject the mixed material into a mold to form a crimping protective sleeve (2); S2-3, cooling and trimming, the formed crimping protective sleeve (2) needs to be cooled in a cooling system, the temperature is controlled within the range of 30°C-60°C, the cooling time is 5-10 minutes, and after cooling, a trimming tool is used to remove burrs and excess parts in the forming process to ensure a smooth surface; S2-4, surface coating, spraying the surface of the crimping protective sleeve (2), adding UV coating or anti-ultraviolet coating to improve its wear resistance and corrosion resistance, and the thickness of the coating is controlled to be 2-3 μm; S2-5, quality inspection, conducting multiple tests on the crimping protective sleeve (2) in terms of size, hardness, temperature resistance and impact resistance to ensure that it meets the design requirements; The manufacturing method of the sealing rubber sleeve (3) comprises the following steps: S3-1, raw material preparation, selecting silicone rubber raw materials according to the ratio requirements, and drying them, wherein the silicone rubber content is ≥85%, the silicon dioxide content is 10%-15%, and the crosslinking agent and plasticizer content is 0.5%-3%; S3-2, mixing process, using an internal mixer to mix silicone rubber, silicon dioxide, crosslinking agent and plasticizer, during the mixing process, ensure that the raw materials are mixed evenly, the temperature is controlled at 80℃-120℃, and the mixing time is 20-30 minutes; S3-3, compression molding, putting the mixed rubber material into a mold, heating it through a compression molding machine, the compression molding temperature is 150℃-180℃, the pressure is controlled at 10-30MPa, and the heating time is 5-10 minutes to ensure that the rubber material is fully cured; S3-4, cooling and trimming, after forming, the sealing rubber sleeve (3) is cooled to room temperature, the excess part is removed and the shape is trimmed; S3-5, aging test: an aging test is performed at a temperature range of 70°C-200°C for 48 hours to ensure the stability and temperature resistance of the sealing rubber sleeve (3) in long-term use.

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