Rigid-flexible composite electric conductor and electric conductor manufacturing method

Abstract

The invention belongs to the technical field of electric conductors, and discloses a rigid-flexible composite electric conductor and an electric conductor manufacturing method. The rigid-flexible composite electric conductor comprises a rigid body section, a flexible compensation section and a connector. The flexible compensation section is connected to at least one end of the rigid body section, and the flexible compensation section can compensate deviation between the rigid body section and a butt joint interface of an external circuit through deformation. The connector is connected to the end, away from the rigid body section, of the flexible compensation section, and the connector can be connected with the butt joint interface. According to the rigid-flexible composite electric conductor, a trunk part of the electric conductor (such as a cable) is replaced by the low-cost rigid body section, so that the production cost and the weight of the electric conductor can be greatly reduced. One end of the rigid body section can compensate production and assembly deviation through deformation of the flexible compensation section, installation convenience is improved, and therefore the advantage of low cost of rigid aluminum materials can be utilized, and the problems of difficult assembly and tolerance sensitivity of the rigid aluminum materials can be solved.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical conductors, and particularly to a rigid-flexible composite electrical conductor and a method for manufacturing an electrical conductor. Background Art

[0002] In current high-current transmission scenarios for electrical connections (such as automotive power systems and industrial power distribution), copper wires are widely used for conducting electricity. Copper wires have good electrical conductivity and flexibility, and are easy to wire and assemble. However, the production cost of copper wires is relatively high and the weight is relatively large.

[0003] However, in order to reduce the cost and weight of cables, some manufacturers replace copper with aluminum, which has relatively low cost and quality, and has the following two forms:

[0004] The first is to directly use aluminum wires to replace copper wires. First, the cost of wire drawing and processing of aluminum wires is relatively high. Second, under the same current-carrying capacity, the diameter of aluminum wires needs to be larger than that of copper wires. Therefore, after replacing copper wires with aluminum wires, it is necessary to design and change the connection terminals, which will also lead to an increase in R & D costs.

[0005] The second is to use rigid aluminum bars (aluminum plates, aluminum bars) formed by one-time extrusion or rolling to replace traditional cable bundles. Although this method has significant advantages in terms of material cost and manufacturing cost of the main part, the rigid aluminum bars lack flexibility and cannot be bent like cables to adapt to complex wiring paths and narrow spaces, resulting in difficult assembly. In addition, the connection point positions at both ends of the rigid aluminum bars are fixed, which puts forward relatively high requirements for the position accuracy of the interfaces of the installed equipment (such as vehicle bodies, cabinets) and the manufacturing accuracy of the aluminum bars themselves, especially for rigid aluminum bars used for assembling to high-precision vehicle bodies. Thus, it also causes a substantial increase in production costs, and in many cases, it is even difficult to achieve large-scale stable mass production. If there are manufacturing tolerances or assembly tolerances, the rigid aluminum bars may not be installed, or there may be stress after installation, affecting the connection reliability and service life. Therefore, the tolerance sensitivity is high.

[0006] Therefore, there is an urgent need for a new type of electrical conductor solution to make up for the problems of difficult assembly and high tolerance sensitivity while taking advantage of the low cost of rigid aluminum materials. Summary of the Invention

[0007] The purpose of the present invention is to provide a rigid-flexible composite electrical conductor and a method for manufacturing an electrical conductor, so as to solve the technical problems of difficult assembly, strict requirements for assembly / manufacturing tolerances, and increased system costs caused by the rigidity when using rigid aluminum bars to replace traditional copper wires in the prior art.

[0008] To achieve this purpose, the present invention adopts the following technical solutions:

[0009] The rigid-flexible composite electrical conductor includes:

[0010] Rigid body section;

[0011] Flexible compensation section, connected to at least one end of the rigid body section, and the flexible compensation section can compensate for the deviation between the rigid body section and the docking interface of the external circuit through deformation; and,

[0012] Connector, connected to the end of the flexible compensation section away from the rigid body section, and the connector can be connected to the docking interface.

[0013] Preferably, one flexible compensation section is connected to each of the two ends of the rigid body section.

[0014] Preferably, the total length of the rigid-flexible composite conductor is L, and the length of the rigid body section is L1, and L1 > L / 5.

[0015] Preferably, the total length of the rigid-flexible composite conductor is L, and the length of the flexible compensation section is L2, and L2 > L / 1000.

[0016] Preferably, the flexible compensation section is a wire harness, a cable, a laminated conductive foil or a conductive braid.

[0017] Preferably, the connector is an exposed section, a connector or a terminal at the end of the flexible compensation section.

[0018] Method for manufacturing a conductor, used for manufacturing a rigid-flexible composite conductor, including the following steps:

[0019] Prepare the rigid body section, the flexible compensation section and the connector;

[0020] Weld the rigid body section and the flexible compensation section by an ultrasonic welder.

[0021] Preferably, preparing the rigid body section includes:

[0022] Obtain the rigid body section by extruding, rolling or stamping aluminum or aluminum alloy materials;

[0023] Preparing the flexible compensation section includes:

[0024] Obtain the flexible compensation section by cutting a wire harness or a cable; or, obtain the flexible compensation section by laminating multiple layers of conductive foils; or, braid conductive wires into a conductive braid to obtain the flexible compensation section.

[0025] Preferably, welding the rigid body section and the flexible compensation section by the ultrasonic welder includes:

[0026] Place the rigid body section on the bottom die of the ultrasonic welder, and stack the flexible compensation section on the rigid body section;

[0027] Adjust the welding parameters of the ultrasonic welder and start the ultrasonic welder;

[0028] Press the welding head of the ultrasonic welder against the flexible compensation section.

[0029] A method for manufacturing an electrical conductor, comprising the following steps:

[0030] Prepare a conductive body section, which is a rigid body section or a flexible body section;

[0031] Cut a flexible conductor having connectors or connection terminals at at least one end to obtain two flexible compensation sections, wherein at least one end of at least one of the flexible compensation sections has a connection head;

[0032] Weld the rigid body section and the flexible compensation section by an ultrasonic welder.

[0033] Advantages of the present invention:

[0034] In the rigid-flex composite electrical conductor of the present invention, the main part of the electrical conductor (such as a cable) is replaced by a low-cost rigid body section. Thus, without changing the current-carrying capacity, the production cost and weight of the electrical conductor can be significantly reduced. Secondly, at least one end of the rigid body section can be connected to the docking interface of the external circuit through a flexible compensation section with a connection head. Since the flexible compensation section has a certain flexibility, it can compensate for the deviation through the deformation of the flexible compensation section in the case of manufacturing deviation and installation deviation of the equipment and the rigid body section. Therefore, the precision of the equipment and the rigid body section in the production and assembly stages can be reduced, a certain degree of cost reduction can be achieved, the installation convenience of the rigid body section can be improved, and the reliability and service life after the installation of the rigid body section can be ensured. In summary, the rigid-flex composite electrical conductor of the present invention can not only utilize the low-cost advantage of rigid aluminum, but also overcome the problems of difficult assembly and tolerance sensitivity of rigid aluminum.

[0035] In the method for manufacturing an electrical conductor of the present invention, after preparing the rigid body section, the flexible compensation section and the connection head, the rigid body section and the flexible compensation section are welded by an ultrasonic welder, and the performance of the material is maintained by low-temperature welding, which helps to improve the performance of the rigid-flex composite electrical conductor; at the same time, it also has the advantages of high efficiency, energy saving, excellent welding quality, strong process adaptability, and low cost.

[0036] In the method for manufacturing an electrical conductor of the present invention, by cutting a flexible conductor having connectors or connection terminals at at least one end to obtain a flexible compensation section, and at least one end of at least one of the flexible compensation sections has a connection head, the existing flexible conductors (such as wire harnesses, cables, laminated conductive foils or conductive braided tapes) can be directly modified, which not only reduces the R & D cost and production cost, but also improves the production efficiency of the composite electrical conductor. Description of the Drawings

[0037] Figure 1 is a schematic structural diagram of Embodiment 1 of the present invention;

[0038] Figure 2 is a schematic diagram of the installation state of the rigid-flexible composite electrical conductor of Embodiment 1 of the present invention on the vehicle body;

[0039] Figure 3 is a schematic structural diagram of the rigid body section and the flexible compensation section in Embodiment 1 of the present invention;

[0040] Figure 4 is a flowchart of the method for manufacturing the electrical conductor in Embodiment 1 of the present invention;

[0041] Figure 5 is a schematic structural diagram of Embodiment 2 of the present invention;

[0042] Figure 6 is a flowchart of the method for manufacturing the electrical conductor in Embodiment 3 of the present invention.

[0043] In the figure:

[0044] 100, vehicle body; 200, solder joint; 1, rigid body section; 2, flexible compensation section; 21, connection hole; 3, connection head. Detailed implementation manners

[0045] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the present invention, rather than limiting the present invention. In addition, it should be noted that for the convenience of description, only the parts related to the present invention are shown in the drawings, rather than all the structures.

[0046] In the description of the present invention, unless otherwise clearly defined and limited, the terms "connected", "connected to", and "fixed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0047] In the present invention, unless otherwise clearly defined and limited, the first feature being "above" or "below" the second feature may include direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on top of" the second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the horizontal height of the first feature is higher than that of the second feature. The first feature being "below", "under" and "beneath" the second feature includes the first feature being directly below and obliquely below the second feature, or simply indicating that the horizontal height of the first feature is lower than that of the second feature.

[0048] In the description of this embodiment, the orientation or positional relationships such as "above", "below", "right", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of description and simplifying the operation, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and thus should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0049] The following refers to Figures 1 to 6 to illustrate the rigid-flexible composite conductor and the method for manufacturing the conductor provided by the present invention.

[0050] The rigid-flexible composite conductor aims to provide a new type of conductor solution to solve the technical problems in the prior art, such as difficult assembly due to its rigidity, strict requirements for assembly / manufacturing tolerances, and increased system costs when using rigid aluminum bars to replace traditional cables. The specific structure and manufacturing method of the rigid-flexible composite conductor are as follows with reference to the following embodiments.

[0051] Embodiment 1

[0052] In a first aspect, this embodiment provides a specific structure of a rigid-flexible composite conductor. Referring to Figure 1 , the rigid-flexible composite conductor includes a rigid body section 1, a flexible compensation section 2, and a connector 3. Among them, the flexible compensation section 2 is connected to at least one end of the rigid body section 1. The connector 3 is connected to the end of the flexible compensation section 2 away from the rigid body section 1, and the connector 3 can be connected to the docking interface.

[0053] Based on the dual requirements of reducing costs and assembly difficulty, first, a low-cost rigid body section 1 replaces the main part of the electrical conductor. Under the same current-carrying capacity, the production cost and weight of the electrical conductor can be significantly reduced. Secondly, the deformation of the flexible compensation section 2 compensates for the angular deviation and position deviation between the rigid body section 1 and the docking interface of the external circuit, which not only improves the installation convenience of the rigid body section 1, but also ensures the reliability and service life of the rigid body section 1 after installation. At the same time, the production accuracy and assembly accuracy of the equipment and the rigid body section 1 can be appropriately reduced, thereby further reducing costs. Finally, while taking advantage of the low-cost advantage of rigid aluminum, the problems of difficult assembly and tolerance sensitivity of the rigid body section 1 are overcome.

[0054] Optionally, the rigid body section 1 is made of aluminum or aluminum alloy material by extrusion, rolling or stamping. Choosing aluminum or aluminum alloy as the raw material of the rigid body section 1 can reduce the raw material cost of the rigid body section 1 because of the low density and low cost of aluminum and aluminum alloy. In addition, multiple die drawing processes are required to produce aluminum wire, the equipment is complex and the production efficiency is low. However, the extrusion, rolling or stamping process has lower costs than the wire drawing process in mass production, thus reducing the processing cost of the rigid body section 1. By adding the reduced raw material cost and processing cost, a significant reduction in production cost is achieved.

[0055] Specifically in this embodiment, in this embodiment, the rigid body section 1 is taken as an aluminum row as an example for detailed description. The aluminum row is made of aluminum by extrusion, and the aluminum row is arranged in a special shape. The specific shape can be adaptively adjusted according to the application scenario, and there is no need to elaborate here. First, the density of aluminum (2.7 g / cm 3 ) is only about 30% of that of copper (8.96 g / cm 3 ). Under the same electrical conductivity, the cross-sectional area of the aluminum row needs to be increased to 1.6 times that of copper, but the weight can still be reduced by about 50%, thus greatly reducing the overall mass of the rigid-flex composite electrical conductor. Referring to Figure 2 , after the rigid-flex composite electrical conductor is installed on the equipment (taking the vehicle body 100 as an example), the weight of the vehicle body 100 can be reduced, which is more competitive in the current situation where automobiles pursue extreme lightweighting.

[0056] Secondly, the aluminum price (about 18,270 yuan / ton) is only 26% of the copper price (about 69,180 yuan / ton), and the cost can be reduced by about 50% in terms of raw material cost.

[0057] Furthermore, the equipment cost of the aluminum extrusion process is significantly lower than that of processes such as rolling and casting, thus controlling the processing cost within a small range.

[0058] Finally, it is worth noting that the aluminum row can be flattened, with better heat dissipation performance, and is more suitable for use in a more compact layout of the vehicle body 100, especially for new energy vehicles with batteries.

[0059] Exemplarily, only one flexible compensation section 2 is provided at one end of the rigid body section 1 in this embodiment, that is, it is applied in the case where deviation is likely to occur at one end of the rigid body section 1, thereby saving the production cost of the rigid-flex composite conductor.

[0060] Optionally, the flexible compensation section 2 is a copper wire, a laminated conductive foil, an aluminum wire or a conductive braid. The copper wire, the laminated conductive foil, the aluminum wire or the conductive braid all have a certain flexibility and can be bent and twisted to a certain extent, so that the deviation can be compensated by the deformation of the flexible compensation section 2.

[0061] As an example, the flexible compensation section 2 in this embodiment is a copper busbar supported by laminated copper foils, and the copper busbar has a certain flexibility; the copper busbar has better heat dissipation performance and less material consumption under the same conductivity, thereby reducing the production cost of the flexible compensation section 2. Among them, the raw material of the copper foil is T2 copper, which has high purity, excellent electrical / thermal conductivity and processing performance; the thickness of a single copper foil is 0.01 - 0.5 mm, the single-layer thickness in this embodiment is 0.2 mm, the total thickness of the copper busbar is 1 - 10 mm, 25 layers of copper foils are stacked in this embodiment, and the total thickness is 5 mm, and the width of the copper busbar is 5 - 40 mm, and the width of the copper busbar in this embodiment is 20 mm.

[0062] Further, the copper busbar is welded to the aluminum busbar, such as ultrasonic welding or explosion welding. Ultrasonic welding is preferably used in this embodiment, and the position of the solder joint 200 is as Figure 3 shown. The welding temperature of ultrasonic welding is only 1 / 3 - 1 / 2 of the melting point of the metal, avoiding the degradation of material properties caused by high temperature, that is, the conductivity and thermal stability of the copper-aluminum conductor are not affected; and the welding time of ultrasonic welding is extremely short, and the energy consumption is much lower than that of traditional welding processes; in addition, the internal resistance of the welded joint is small, and the conductivity is close to that of the base material, which is suitable for high-current applications (such as new energy wire harnesses); furthermore, ultrasonic welding can weld dissimilar metals (copper-aluminum composite) and has a high tolerance for surface oxide layers.

[0063] Further, the total length of the rigid-flex composite conductor is L, the length of the rigid body section 1 is L1, and L1 > L / 5. The minimum length of the rigid body section 1 is limited, so that the cost and quality of the rigid-flex composite conductor are significantly reduced compared with those of copper wires or aluminum wires. The length of the flexible compensation section 2 is L2, and L2 > L / 1000. The minimum length of the flexible compensation section 2 is limited, so that the flexible compensation section 2 has a certain length and can compensate a certain deviation. As an example, in this embodiment, L1 = 4 / 5 * L and L2 = 1 / 5 * L, thus taking into account the production cost and the ability to compensate for deviations. It should be noted that the listed values do not constitute a limitation, and other values not listed within this range are equally applicable and can be adjusted adaptively according to actual needs.

[0064] Optionally, the connection head 3 is the exposed section, connector or terminal at the end of the flexible compensation section 2. In this embodiment, only the exposed section at the end of the flexible compensation section 2 is taken as an example, that is, a section of the copper bar away from the rigid body section 1 also serves as the connection head 3, and a connection hole 21 is provided. Of course, in some other embodiments, the connection head 3 can also be selected to be connected to a connector or terminal and connected to the end of the flexible compensation section 2.

[0065] On the other hand, this embodiment provides a method for manufacturing an electrical conductor for manufacturing the above-mentioned rigid-flex composite electrical conductor. Refer to Figure 1 and Figure 4 , the manufacturing method of the rigid-flex composite electrical conductor includes the following steps:

[0066] S1. Prepare the rigid body section 1, the flexible compensation section 2 and the connection head 3.

[0067] In step S1, the aluminum bar is formed by extruding aluminum through an extrusion die to obtain the rigid body section 1. The equipment cost of the aluminum extrusion process is significantly lower than that of processes such as rolling and casting, thereby controlling the processing cost within a small range. Optionally, in some other embodiments, aluminum alloy can also be used to replace aluminum; the aluminum bar can also be formed by rolling aluminum through a rolling mill; the aluminum bar can also be formed by stamping aluminum through a stamping machine.

[0068] The flexible compensation section 2 is obtained by laminating multiple layers of copper foils through a laminating machine; the copper bar has better heat dissipation performance and less material consumption under the same electrical conductivity, thereby reducing the production cost of the flexible compensation section 2. Optionally, in some other embodiments, the flexible compensation section 2 can be obtained by intercepting a cable; or, the flexible compensation section 2 can be obtained by braiding conductive wires into a conductive braid.

[0069] In this embodiment, a section of the copper bar away from the rigid body section 1 also serves as the connection head 3. Therefore, the connection head 3 and the flexible compensation section 2 are integrally arranged, and there is no need to separately prepare the connection head 3. Thus, while reducing the production cost, the operation process is reduced to achieve cost reduction and efficiency improvement. However, in some other embodiments, the connection head 3 can be a connector or terminal, and then it needs to be separately prepared.

[0070] S2. Weld the rigid body section 1 and the flexible compensation section 2 through an ultrasonic welder.

[0071] Specifically, step S2 includes: S21. Place the rigid body section 1 on the bottom die of the ultrasonic welder; S22. Stack the flexible compensation section 2 on the rigid body section 1; S23. Start the ultrasonic welder and press the welding head of the ultrasonic welder against the flexible compensation section 2.

[0072] By performing the welding of the rigid body segment 1 and the flexible compensation segment 2 through the above steps, that is, the welding of the aluminum row and the copper row, the energy transfer efficiency can be optimized. That is, the copper row, as a high thermal conductivity material, is placed on the side of the welding head, which can quickly conduct the ultrasonic vibration energy to the welding interface, reducing energy loss. The aluminum row is placed on the side of the bottom mold, and its softer material can better absorb vibration and form plastic deformation, enhancing the bonding strength of the welding surface. Secondly, the copper row can stably support the welding pressure, avoiding uneven deformation of the aluminum row due to its excessive softness, thereby more effectively breaking the oxide layer on the aluminum surface. Of course, in some other embodiments, the positions of the aluminum row and the copper row can also be swapped.

[0073] Furthermore, the surface of the bottom mold of the ultrasonic welding machine has inclined teeth, that is, the aluminum row is placed on the inclined teeth. The inclined tooth structure, through the directional concave and convex textures, promotes stronger relative movement of the aluminum row under ultrasonic vibration, accelerating the destruction of the surface oxide layer. The shear force direction of the inclined teeth forms an angle with the vibration wave propagation direction, which can improve the plastic deformation efficiency of the metal contact surface and shorten the welding time. The geometric shape of the inclined teeth can more evenly disperse the ultrasonic energy, avoiding damage to the aluminum row caused by local stress concentration. The periodic texture of the inclined teeth helps to form a microscopic mechanical interlocking structure, increasing the metal residual contact surface of the welded joint to more than 80%, significantly reducing the contact resistance.

[0074] Optionally, step S2 further includes: before the flexible compensation segment 2 is superimposed on the rigid body segment 1, pre-shaping the flexible compensation segment 2, that is, pressing the flexible compensation segment 2 into a sheet through a metal flattening device or a metal shaping device to make the flexible compensation segment 2 flat, so as to increase the contact area between the flexible compensation segment 2 and the rigid body segment 1 and improve the welding quality.

[0075] It should be added that if the connector 3 is a connector and a terminal, it is necessary to connect the connector 3 to the flexible compensation segment 2, that is, weld the joint of the connector to the end of the flexible compensation segment 2; the terminal is pressed on the end of the flexible compensation segment 2, and this step can be carried out before step S2 or after step S2.

[0076] The following gives examples of the welding parameters for the aluminum row and the copper row themselves. Among them, the aluminum row is 25 mm wide and 5 mm thick, the thickness of the copper row is 5 mm, the width of the copper row is 20 mm, and the copper row is formed by stacking 25 layers of copper foils with a single thickness of 0.2 mm.

[0077] Examples of welding parameters are as follows: welding pressure 30 - 50 PSI, amplitude 20 - 40 microns, welding time 2 - 5 seconds, energy range 16000 - 25000 joules, power 5000 - 8000 watts.

[0078] Embodiment 2

[0079] The difference between this embodiment and the first embodiment is that: two flexible compensation sections 2 are connected to both ends of the rigid body section 1 respectively, so that the deviations at both ends of the rigid body section 1 can be compensated by the two flexible compensation sections 2 to adapt to the scenario where precise positioning is required at both ends of the rigid body section 1, such as the automobile body 100; compared with the case where the flexible compensation section 2 is only provided at one end, the installation is more convenient, and the anti-vibration performance is better, the service life is longer, and the residual stress in the installation area is smaller. In addition, a connector 3 is connected to each end of each flexible compensation section 2 away from the rigid body section 1, and the connector 3 is a terminal.

[0080] Embodiment Three

[0081] The difference between this embodiment and the first embodiment is that: this embodiment provides a method for manufacturing an electrical conductor, including the following steps:

[0082] S1. Prepare the conductive body section. The conductive body section in this embodiment is the rigid body section 1. Specifically, an aluminum row is formed by extruding aluminum through an extrusion die to obtain the rigid body section 1.

[0083] S2. Cut a flexible conductor with a connector or a connection terminal at at least one end to obtain two flexible compensation sections, wherein at least one end of the flexible compensation section has a connector.

[0084] As an example, the flexible conductor in this embodiment is a cable with connectors at both ends, so that two flexible compensation sections 2 with connectors 3 at their ends are obtained after cutting the cable. In some other alternative embodiments, a cable with a connector or a connection terminal only at one end can also be selected. Optionally, in some other embodiments, the flexible conductor can also be a wire harness, a laminated conductive foil or a conductive braid.

[0085] By directly cutting the flexible compensation section 2 with a connector 3 from the finished cable through the above steps, it is not necessary to separately prepare the flexible compensation section 2 and the connector 3, nor to connect the flexible compensation section 2 and the connector 3. This can not only save the relevant R & D investment, but also reduce the production process and production difficulty, and can reduce the production cost of the electrical conductor and improve the production efficiency relying on the mature supply chain of the existing cable.

[0086] Optionally, in some other embodiments, step S1 and step S2 can be carried out synchronously; or, step S2 can be carried out before step S1.

[0087] Exemplarily, taking a copper cable with a length of 2 meters and a cross-sectional area of 95 square millimeters as an example, in step S2, 1.6 meters of the middle part of the copper cable is removed; the length of the prepared rigid body section 1 is 1.7 meters, and the cross-sectional area is 200 square millimeters.

[0088] S3. Weld the rigid body section 1 and the flexible compensation section 2 by an ultrasonic welder.

[0089] Specifically, step S3 includes: S31. Process the end of the flexible compensation section 2 to expose the end of the flexible compensation section 2, and make the end shape of the flexible compensation section 2 consistent with the end shape of the rigid body section 1; in this way, the ends of the flexible compensation section 2 and the rigid body section 1 can be neatly butted, which helps to improve the welding quality between the two. S32. Weld the two ends of the rigid body section 1 and the ends of the two flexible compensation sections 2 end to end in sequence.

[0090] Optionally, in some other embodiments, the flexible body section can also be a conductive body section, and the flexible body section can be an aluminum cable. In this way, the middle part of the copper cable can be replaced by the aluminum cable, so that a composite conductor is formed after welding the aluminum cable and the copper cable. While reducing the production cost, the middle section of the composite conductor has a certain flexibility and can be bent for wiring.

[0091] S4. After welding, use a solder joint injection molding device to perform insulation sealing on the two solder joints. By injecting and wrapping the solder joints, it can prevent external dust, moisture, and oil from invading the solder joints 200, reduce the risk of short circuit or oxidation, and can also enhance the mechanical strength and reduce the cracking of the solder joints 200 caused by vibration or collision.

[0092] Obviously, the above embodiments of the present invention are only examples for clearly illustrating the present invention, rather than limiting the implementation manners of the present invention. For those of ordinary skill in the art, various obvious changes, re-adjustments, and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the implementation manners here. Any modifications, equivalent substitutions, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A rigid-flexible composite electrical conductor, characterized in that, Comprising: A rigid body section (1); A flexible compensation section (2), connected to at least one end of the rigid body section (1), and the flexible compensation section (2) can compensate for the deviation between the rigid body section (1) and the docking interface of the external circuit through deformation; and A connector (3), connected to the end of the flexible compensation section (2) away from the rigid body section (1), and the connector (3) can be connected to the docking interface.

2. The rigid-flexible composite electrical conductor according to claim 1, characterized in that, One flexible compensation section (2) is connected to each of the two ends of the rigid body section (1).

3. The flexible and rigid composite electrical conductor according to claim 1, characterized in that The total length of the rigid-flexible composite conductor is L, and the length of the rigid body section (1) is L1, where L1 > L / 5.

4. The rigid-flexible composite electrical conductor according to claim 1, wherein The total length of the rigid-flexible composite conductor is L, and the length of the flexible compensation section (2) is L2, where L2 > L / 1000.

5. The rigid-flexible composite electrical conductor according to any one of claims 1-4, characterized in that, The flexible compensation section (2) is a wire harness, a cable, a laminated conductive foil, or a conductive braid.

6. The rigid-flexible composite electrical conductor according to any one of claims 1-4, characterized in that, The connector (3) is an exposed section, a connector, or a terminal at the end of the flexible compensation section (2).

7. A method for manufacturing an electrical conductor, characterized in that, For manufacturing the rigid-flexible composite conductor according to any one of claims 1-6, comprising the following steps: Preparing the rigid body section (1), the flexible compensation section (2), and the connector (3); Welding the rigid body section (1) and the flexible compensation section (2) by an ultrasonic welder.

8. The method for manufacturing an electrical conductor according to claim 7, characterized in that, Preparing the rigid body section (1) includes: Obtaining the rigid body section (1) by extruding, rolling, or stamping aluminum or aluminum alloy materials; Preparing the flexible compensation section (2) includes: Obtaining the flexible compensation section (2) by cutting a wire harness or a cable; or obtaining the flexible compensation section (2) by laminating multiple layers of conductive foils; or obtaining the flexible compensation section (2) by braiding conductive wires into a conductive braid.

9. The method for manufacturing an electrical conductor according to claim 7, characterized in that, Welding the rigid body section (1) and the flexible compensation section (2) by the ultrasonic welder includes: Placing the rigid body section (1) on the bottom die of the ultrasonic welder, and stacking the flexible compensation section (2) on the rigid body section (1); Adjusting the welding parameters of the ultrasonic welder and starting the ultrasonic welder; Pressing the welding head of the ultrasonic welder against the flexible compensation section (2).

10. A method for manufacturing an electrical conductor, characterized in that, Including the following steps: Preparing a conductive body section, and the conductive body section is a rigid body section (1) or a flexible body section; Cutting a flexible conductor with connectors or connection terminals at at least one end to obtain two flexible compensation sections (2), wherein at least one end of the flexible compensation section (2) has a connector (3); Welding the rigid body section (1) and the flexible compensation section (2) by an ultrasonic welder.

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