Aluminum row connecting piece for battery and manufacturing method of aluminum row connecting piece

Abstract

The invention relates to the field of electric connecting pieces, and discloses an aluminum bar connecting piece for a battery and a manufacturing method of the aluminum bar connecting piece, and the aluminum bar connecting piece comprises a 6101 aluminum alloy substrate which is used as a conductor for bearing current; the insulating layer is coated on the outer surface of the 6101 aluminum alloy substrate; the electroplated layers are formed on the surfaces of the two ends of the 6101 aluminum alloy substrate; the manufacturing method of the aluminum row connecting piece for the battery comprises the following steps: forming an aluminum row, and selecting a 6101 aluminum alloy plate; coating an insulating layer, and curing the polyimide solution to form a polyimide insulating film on the surface of the aluminum bar; machining to enable the aluminum row to meet the assembly requirement; and electroplating treatment: carrying out electroplating process treatment on the surfaces of the two ends of the aluminum bar. The technical problems that in the prior art, an aluminum bar is poor in insulation and voltage-resistant performance, and an insulated heat-shrinkable sleeve occupies the internal space of a battery are solved, the effect of improving oxidation resistance through the polyimide insulation film is achieved, the thickness of the aluminum bar is reduced, and meanwhile the insulation and voltage-resistant performance of the aluminum bar is also improved.

Description

Technical Field

[0001] The present application relates to the field of electrical connectors, and in particular to an aluminum busbar connector for a battery and a method for manufacturing the same. Background Art

[0002] Battery electrical connectors refer to conductors used to carry current between components in a battery circuit. Aluminum busbars are characterized by light weight, high strength, and good electrical conductivity, making them ideal materials for battery connections. Aluminum busbar electrical connectors are widely used in power battery systems, energy storage systems, photovoltaic power generation systems, and industrial automation for new energy vehicles. They are essential to ensure the safe and reliable operation of electrical systems and to improve the performance of the overall system.

[0003] However, in the process of implementing relevant technical solutions, it was found that at least the following technical problems exist: the current insulation method for the aluminum busbar is a heat shrink tubing, which is thicker and increases the space occupancy inside the battery. The insulation and voltage resistance performance of the heat shrink tubing is also poor, and the oxidation problem of the aluminum busbar has always existed. Summary of the invention

[0004] The present application provides an aluminum busbar connector for a battery, thereby solving the technical problems in the prior art that the insulation and pressure resistance of the aluminum busbar is poor and the insulating heat shrink tubing occupies the internal space of the battery. The application utilizes a polyimide insulating film to reduce the thickness of the aluminum busbar, thereby improving the insulation and pressure resistance of the aluminum busbar and reducing the problem of oxidation.

[0005] The present application provides an aluminum busbar connector for a battery, comprising: a 6101 aluminum alloy substrate, serving as a conductor for carrying current; an insulating layer, covering the outer surface of the 6101 aluminum alloy substrate; and an electroplating layer, formed on the surfaces of both ends of the 6101 aluminum alloy substrate.

[0006] Furthermore, the electroplating layer is a tin-plated layer formed after metal surface treatment.

[0007] Furthermore, the electroplated layer is a nickel-plated layer formed after metal surface treatment.

[0008] Furthermore, the film-like insulating layer is an insulating film formed by coating a polyimide solution and then curing it at high temperature.

[0009] The present application also provides a method for manufacturing an aluminum busbar connector for a battery, comprising the following steps: aluminum busbar forming, selecting a 6101 aluminum alloy plate, and subjecting the plate to an aluminum busbar forming process according to design requirements to form the plate into the shape and size required by the design; insulating layer coating, coating a polyimide solution on the surface of the aluminum busbar, and forming a polyimide insulating film on the surface of the aluminum busbar after curing; machining, machining the aluminum busbar so that the aluminum busbar meets the assembly requirements; electroplating, performing an electroplating process on the surfaces of both ends of the aluminum busbar so that a layer of electroplating is formed on the surface of the aluminum busbar.

[0010] Furthermore, the insulating layer coating includes the following steps: raw material preparation, the raw materials include polyimide solution, curing agent, and catalyst; coating, the polyimide solution is evenly coated on the aluminum busbar; pre-curing, curing at a relatively low temperature so that a polyimide network structure is formed on the surface of the aluminum busbar; post-curing, curing at a relatively high temperature so that the polyimide network structure on the surface of the aluminum busbar forms a complete polymer network structure; cooling, the polyimide insulating film on the surface of the aluminum busbar is cooled to room temperature in an inert gas.

[0011] Furthermore, the thickness of the polyimide insulating film is 0.1 mm-0.25 mm.

[0012] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0013] A polyimide insulating film is coated on 6101 aluminum alloy as an aluminum busbar connector. Not only is the film thickness relatively thin, but the pressure resistance, temperature resistance, wear resistance and anti-puncture performance are all better than those of the existing copper busbar and aluminum busbar. Moreover, under the same test current, the temperature rise rate is relatively slow within the same time period, and the hardness of the screw joint of the aluminum busbar connector of the present application is consistent with that of the soft copper busbar. Therefore, the technical problems in the prior art that the insulation and pressure resistance performance of the aluminum busbar is poor and the insulating heat shrinkable sleeve occupies the internal space of the battery are solved, the anti-oxidation effect is improved by using the polyimide insulating film, the thickness of the aluminum busbar is reduced, and the insulation and pressure resistance performance of the aluminum busbar is also improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the layer structure of an aluminum busbar connector for a battery in Example 1 of the present application;

[0015] Figure 2 This is a schematic structural diagram of an aluminum busbar connector for a battery in Example 1 of the present application;

[0016] Figure 3 This is a flow chart of a method for manufacturing an aluminum busbar connector for a battery in Example 2 of the present application;

[0017] Figure 4 This is a flow chart of the insulating layer coating in Example 2 of the present application.

[0018] In the figure: 100, 6101 aluminum alloy substrate; 200, electroplating layer; 300, insulating layer; 1, aluminum busbar connector; 11, connecting hole. DETAILED DESCRIPTION

[0019] The embodiment of the present application discloses an aluminum busbar connector for a battery and a method for manufacturing the same. The aluminum busbar connector includes: a 6101 aluminum alloy substrate; an insulating layer; and an electroplating layer. The method for manufacturing an aluminum busbar connector for a battery includes the following steps: aluminum busbar molding, selecting a 6101 aluminum alloy plate as the current-carrying function; insulating layer coating, coating the surface of the aluminum busbar with a polyimide solution; machining, machining the aluminum busbar; electroplating, performing an electroplating process on the surfaces of both ends of the aluminum busbar, which solves the technical problems in the prior art that the insulation and pressure resistance of the aluminum busbar is poor and the insulating heat shrink tubing occupies the internal space of the battery, thereby improving the insulation and pressure resistance of the aluminum busbar and reducing the problem of oxidation.

[0020] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0021] Embodiment 1

[0022] A battery aluminum bar connector, referring to Figure 1 , is a schematic diagram of the layer structure of the aluminum busbar connector of the present application, including a 6101 aluminum alloy substrate 100, an insulating layer 200, and an electroplating layer 300. The 6101 aluminum alloy substrate 100 is a basic conductor that carries current. The insulating layer 200 is a protective film that covers the outer surface of the 6101 aluminum alloy substrate 100. The electroplating layer 300 is formed on the surfaces of both ends of the 6101 aluminum alloy substrate 100. Figure 2 As shown, Figure 2 This is a schematic diagram of the structure of the aluminum busbar connector of the present application. The length of the insulating layer 200 is smaller than the length of the aluminum busbar connector 1. Both ends of the aluminum busbar connector 1 extend out of the insulating layer 200. The extended ends of the aluminum busbar connector are both provided with connecting holes 11, which are used for assembling the aluminum busbar connector.

[0023] 6101 aluminum alloy is a high-strength non-heat-treated aluminum alloy with good electrical conductivity and welding performance. The yield strength and tensile strength of 6101 aluminum alloy can vary within a certain range to meet different application requirements. The insulating layer 200 formed by high-temperature curing after polyimide solution coating is coated on the 6101 aluminum alloy substrate 100. The formed polyimide insulating film can effectively prevent the 6101 aluminum alloy substrate 100 from being oxidized in an aerobic environment. The thickness of the polyimide insulating film is 0.1mm-0.25mm. The electroplating layer 300 is a tin-plating layer or a nickel-plating layer formed after surface treatment at both ends of the 6101 aluminum alloy substrate 100. Regardless of nickel plating or tin plating, this electroplating layer 300 can block oxygen and water vapor after being electroplated on the 6101 aluminum alloy substrate 100 to prevent the 6101 aluminum alloy substrate 100 from reacting and corroding with the external environment.

[0024] Referring to the figure below, there is a schematic diagram comparing the different performances of the soft copper busbar and the soft aluminum busbar whose existing insulation method is a heat shrink tubing and the aluminum busbar in this application.

[0025]

[0026] As can be seen from the above figure, the pressure resistance, temperature resistance, wear resistance and anti-puncture performance of the aluminum busbar connector in this application are better than those of the existing copper busbar and aluminum busbar, and the film thickness is even thinner. Since the resistance of aluminum is greater than that of copper, a larger cross-section needs to be added to meet the design overcurrent requirements, and the internal space of the battery requires a thinner insulation layer thickness of the aluminum conductive busbar to meet the space requirements, which solves the current problem of the large space occupancy of the internal battery by the aluminum busbar.

[0027] In addition, experiments have shown that the aluminum busbar electrical connector of the present application heats up slowly when carrying current. Refer to the figure below, which is a temperature comparison of the existing soft copper busbar and soft aluminum busbar with the aluminum busbar in the present application under the same test current in the same time period.

[0028]

[0029] As can be seen from the above figure, the aluminum busbar connector in the present application heats up more slowly within the same time period under the same test current. Therefore, the aluminum busbar connector in the present application has a better low-rate heating effect.

[0030] Furthermore, the screw connection points of the aluminum busbar connector of the present application are compared with existing electrical connectors under the Webster hardness test and the Rockwell hardness test, as shown in the following figure.

[0031] Test Name Soft aluminum bar--nickel sheet Soft copper busbar--nickel sheet This application aluminum bar - nickel sheet Webster Hardness Test (HW) 1～3 11～13 11～13 Rockwell Hardness Test (HBF) ＜30 70～82 70～82

[0032] As can be seen from the above figure, the screw connection point of the aluminum busbar connector in the present application is consistent with the hardness of the soft copper busbar. Therefore, the aluminum busbar connector in the present application has the same connection hardness as soft copper.

[0033] In summary, due to the use of 6101 aluminum alloy substrate as battery connectors and polyimide insulating film as insulating film, when the film thickness is reduced, the pressure resistance, temperature resistance, wear resistance, and anti-puncture performance of the aluminum busbar connector are better than those of the existing copper busbar and aluminum busbar, and the anti-oxidation effect is better, which effectively solves the problem that battery connectors are easily oxidized in an aerobic environment. In addition, the insulating film with a thickness of only 0.1mm-0.25mm formed after high-temperature curing with polyimide liquid coating can achieve a thin insulating film to solve the problem of space requirements caused by the large cross-sectional design area of ​​the aluminum busbar.

[0034] Embodiment 2

[0035] A method for manufacturing an aluminum busbar connector for a battery, such as Figure 3 As shown, the following steps are included:

[0036] S1, aluminum row forming.

[0037] In the specific implementation, 6101 aluminum alloy plate is selected, and according to the design requirements, it is formed into the shape and size required by the design through an aluminum sheet forming process. The aluminum sheet forming process may include cutting, grinding, stamping, bending, stretching, cleaning and other processes.

[0038] S2, insulation coating.

[0039] In a specific implementation, the step of coating the insulating layer can be as follows: Figure 4 As shown, the following steps are included:

[0040] S21, raw material preparation, the raw materials include polyimide solution, curing agent, and catalyst;

[0041] S22, coating, coating the polyimide solution evenly on the aluminum bar;

[0042] S23, pre-curing, curing at a relatively low temperature so that a polyimide network structure is formed on the surface of the aluminum row;

[0043] S24, post-curing, curing at a higher temperature, so that the polyimide network structure on the surface of the aluminum bar forms a complete polymer network structure;

[0044] S25, cooling, the polyimide insulating film on the surface of the aluminum busbar is cooled to room temperature in an inert gas.

[0045] S3, machining.

[0046] In a specific implementation, the aluminum bar is subjected to mechanical processing, such as drilling and cutting, so that the aluminum bar meets the assembly requirements, which may involve threaded connection, riveting or other mechanical fixing methods.

[0047] S4, electroplating treatment.

[0048] In a specific implementation, an electroplating process is performed on the surfaces of both ends of the aluminum bar, so that an electroplating layer is formed on the surface of the aluminum bar. The electroplating layer may be a tin-plated layer or a nickel-plated layer.

[0049] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

[0050] What has been described above is only a preferred specific implementation manner of the embodiments of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can make equivalent substitutions or changes according to the technical scheme and concept of the present application within the technical scope disclosed in the present application, which should be covered by the protection scope of the present application.

Claims

1. A battery aluminum bar connector, characterized in that: include: 6101 aluminum alloy substrate (100), serving as a conductor for carrying current; An insulating layer (200) coated on the outer surface of the 6101 aluminum alloy substrate (100); The electroplating layer (300) is formed on the surfaces of both ends of the 6101 aluminum alloy substrate (100).

2. The aluminum bar connector for a battery as claimed in claim 1, characterized in that: The electroplating layer (300) is a tin-plated layer formed after metal surface treatment.

3. A battery aluminum bar connector as claimed in claim 2, characterized in that: The electroplating layer (300) is a nickel-plated layer formed after metal surface treatment.

4. The aluminum bar connector for a battery as claimed in claim 1, characterized in that: The insulating layer (200) is a polyimide insulating film formed by coating a polyimide solution and then curing it at high temperature.

5. A method for manufacturing the aluminum bar connector for a battery as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: Aluminum bar forming: select 6101 aluminum alloy plate and form it into the shape and size required by the design through aluminum bar forming process according to the design requirements; Insulation layer coating: coating a polyimide solution on the surface of the aluminum busbar, and forming a polyimide insulation film on the surface of the aluminum busbar after curing; Machining: machining the aluminum bar to make it meet the assembly requirements; Electroplating treatment is performed on the surfaces of both ends of the aluminum busbar, so that a layer of electroplating layer is formed on the surface of the aluminum busbar.

6. The method for manufacturing an aluminum busbar connector for a battery as claimed in claim 5, characterized in that: Insulation coating The following steps are involved: Raw material preparation, including polyimide solution, curing agent and catalyst; Coating, coating the polyimide solution evenly on the aluminum bar; Pre-curing, curing at a lower temperature, so that the surface of the aluminum bar forms a polyimide network structure; Post-curing, curing at a higher temperature, so that the polyimide network structure on the surface of the aluminum bar forms a complete polymer network structure; Cooling: The polyimide insulating film on the surface of the aluminum busbar is cooled to room temperature in an inert gas.

7. The method for manufacturing an aluminum busbar connector for a battery as claimed in claim 5, characterized in that: The thickness of the polyimide insulating film is 0.1mm-0.25mm.

Images