Laminated busbar polar plate assembly and processing technology

Abstract

The laminated busbar polar plate assembly comprises a plurality of layers of aluminum polar plate bodies which are arranged in an up-and-down laminated mode, and the edge of each polar plate body is further connected with a plurality of copper connecting terminals; the pole plate bodies located on the top layer and the bottom layer are fixed to the connecting terminals on the layer in an up-down lap joint mode, and the pole plate body located between the bottom layer and the bottom layer is fixed to the connecting terminals on the layer in a butt joint mode. The connection strength of the edge layer is improved by increasing the contact area through lap joint fixation; and the longitudinal space occupation is reduced through butt joint fixation, so that the overall structure of the laminated busbar is more compact. The friction stir welding process is adopted for welding the aluminum polar plate and the copper terminal, the process is solid-phase welding, the defects of air holes, cracks, intermetallic compounds and the like generated during dissimilar metal fusion welding can be avoided, it is ensured that the conductivity of a connector is stable, the mechanical strength is high, and the vibration resistance and the thermal cycle resistance of the polar plate assembly are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of laminated busbar technology, specifically to a laminated busbar electrode plate assembly and its processing technology. Background Technology

[0002] Laminated busbars, also known as composite busbars, are products with a multi-layered conductor and insulator composite structure. They have a larger surface area, allowing for better heat dissipation and convection. Compared to traditional wiring devices, laminated busbars significantly save at least 50% of space. They are widely used in high-power equipment such as new energy vehicles, energy storage systems, and frequency converters.

[0003] In the existing processing methods of laminated busbars, the electrode assembly mostly uses a single material, resulting in a large waste of material. When using dissimilar materials, due to the large differences in physical properties between aluminum and copper (different melting points, thermal conductivity, and coefficients of thermal expansion), traditional welding processes (such as argon arc welding and brazing) are prone to producing defects such as porosity, cracks, and intermetallic compounds, which leads to a decrease in the conductivity of the joint, insufficient mechanical strength, and the easy occurrence of false welds during the welding process, which hides safety hazards. Summary of the Invention

[0004] In view of the deficiencies in the prior art, the first objective of the present invention is to provide a stacked busbar electrode assembly that can balance the robustness of the connection of the stacked busbars with the compactness of the structure.

[0005] The technical solution adopted in this invention is: a stacked busbar electrode assembly, comprising multiple layers of aluminum electrode bodies arranged in a stacked manner, each electrode body having several copper connecting terminals connected to its edge; the electrode bodies and connecting terminals are fixedly connected or joined vertically; the electrode bodies located at the top and bottom layers are fixedly connected to the connecting terminals of that layer vertically, the electrode bodies located between the bottom and bottom layers are fixedly joined to the connecting terminals of that layer, and an insulating plate is provided between adjacent electrode bodies.

[0006] In this technical solution, after the stacked busbars are stacked, adjacent electrode bodies are isolated by an insulating plate to ensure insulation. The connecting terminals connected to the edges of the electrode bodies adopt different fixing methods depending on their positions. During assembly, the electrode bodies at the top and bottom layers are fixed to the connecting terminals by overlapping to ensure a firm fixation and prevent the connecting terminals from breaking or falling off. The electrode bodies between the top and bottom layers are connected to the connecting terminals of that layer by butt joints. This method can significantly save longitudinal connection space while ensuring the stability of the connection between the connecting terminals and the electrode bodies, making the stacked busbars more compact overall.

[0007] Preferably, the edge of the electrode body that overlaps and is fixed with the connecting terminal is formed with an overlap groove.

[0008] Preferably, the electrode plate body and the connecting terminal are fixed by welding after overlapping or butting, and the weld seam is a straight line or a curved structure.

[0009] Preferably, the electrode plate body is provided with electrode holes for mounting capacitor cores, and the insulating plate is provided with through holes in the area corresponding to the electrode holes.

[0010] The second objective of this invention is to provide a processing technology for laminated busbar electrode plates, which improves the production efficiency and quality of laminated busbar electrode plates; specifically, it includes the following steps;

[0011] S1. Parts processing: The aluminum plate and copper plate raw materials are processed into parts of qualified product size according to the design specifications of the electrode body and the connecting terminal.

[0012] S2. Clamping and positioning: Use tooling fixtures to fix the electrode body and connecting terminal parts by overlapping or butting them together at the welding station. During fixing, the connecting terminal is positioned and fixed according to the shape, and the electrode body is fixed through the inner hole.

[0013] S3. Welding, which involves welding the lap and butt joint areas using friction stir welding.

[0014] Preferably, in S1, the electrode body and the connecting terminal are formed by laser cutting or stamping.

[0015] Preferably, in S2, when the electrode plate body and the connecting terminal overlap, the overlap area is not less than 20mm. 2 .

[0016] Preferably, in S2, when the electrode body is mated with the connecting terminal, the mating gap between the electrode body and the connecting terminal is less than 0.3 mm.

[0017] Preferably, in S3, when the electrode body and the connecting terminal are connected, the welding head rotates at 2600-3200 r / min and the feed speed is 3-7 m / min.

[0018] Preferably, in S3, when the electrode body and the connecting terminal are mated, the welding head rotates at 600-1000 r / min, the feed speed is 3-7 m / min, and the center of the weld is offset to one side of the electrode body by 0.5-2 mm.

[0019] The aforementioned processes clearly define standardized requirements for part machining, clamping and positioning, and welding parameters, reducing human error. Specifically, laser cutting / stamping ensures part dimensional accuracy, while the internal hole positioning and external shape positioning methods of the tooling fixtures improve clamping accuracy. Precise welding parameters adapt to the welding requirements of different connection methods, significantly improving product yield and production efficiency, and reducing mass production costs.

[0020] The beneficial effects of this invention are as follows: The laminated busbar electrode assembly of this invention adopts a composite design of lap joint fixing and butt joint fixing, taking into account the stress characteristics of the top, bottom, and middle layer electrode plates. Lap joint fixing increases the contact area and enhances the connection strength of the edge layers, preventing terminal vibration and detachment. Butt joint fixing reduces the longitudinal space occupation, making the overall structure of the laminated busbar more compact. This solves the space and strength contradiction of existing single fixing methods and adapts to the miniaturization requirements of equipment. The aluminum electrode plates and copper terminals are welded using friction stir welding. This solid-state welding process avoids defects such as porosity, cracks, and intermetallic compounds that occur during dissimilar metal fusion welding. Combined with precise welding parameters, it ensures stable conductivity and high mechanical strength of the joint, significantly improving the electrode assembly's vibration resistance and thermal cycling resistance, and has high practical value. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0022] Figure 1 This is a perspective view of the stacked busbar electrode assembly and its processing technology provided in an embodiment of the present invention.

[0023] Figure 2 This is a cross-sectional view of the stacked busbar electrode assembly and its processing technology provided in an embodiment of the present invention.

[0024] Reference numerals in the attached drawings: electrode body 100, overlapping groove 110, electrode hole 120, connecting terminal 200, and insulating plate 300. Detailed Implementation

[0025] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the technical solution of the present invention and are therefore intended to limit the scope of protection of the present invention.

[0026] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application should have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0027] Example 1

[0028] like Figure 1 and Figure 2As shown, a specific embodiment of the present invention provides a stacked busbar electrode assembly, including multiple aluminum electrode bodies 100 arranged in layers, and each electrode body 100 is connected to a plurality of copper connecting terminals 200 on its edge; wherein, the electrode body 100 is made of industrial aluminum, and the copper connecting terminals 200 uniformly distributed on the edge of each electrode body 100 are made of copper. An insulating layer 300 is provided between adjacent electrode bodies 100; the electrode bodies 100 and the connecting terminals 200 are fixed by overlapping or butting. In this embodiment, during assembly, the electrode bodies 100 located at the top and bottom layers are fixed by overlapping with the connecting terminals 200 of that layer, and the electrode bodies 100 located between the bottom and bottom layers are fixed by butting with the connecting terminals 200 of that layer. The electrode bodies 100 and the connecting terminals 200 are fixed by welding after overlapping or butting. The weld structure includes, but is not limited to, a straight structure or a curved structure. The weld of the curved structure is S-shaped. The S-shaped weld structure can increase strength and reduce temperature rise during welding, and can effectively deal with the situation where the butt joint is too short during welding.

[0029] like Figure 1 and Figure 2 As shown, after the above settings, the stacked busbars are isolated from adjacent electrode bodies 100 by the insulating plate 300 to ensure insulation. The connecting terminals 200 connected to the edges of the electrode bodies 100 adopt different fixing methods according to their positions. The electrode bodies 100 located at the top and bottom layers are fixed to the connecting terminals 200 by overlapping to ensure the fixation is firm and to prevent the connecting terminals 200 from breaking and falling off. The electrode bodies 100 located between the top and bottom layers are connected to the connecting terminals 200 of that layer by butt joint. While ensuring the connection stability between the connecting terminals 200 and the electrode bodies 100, the longitudinal connection space can be significantly saved, ensuring that the stacked busbars are more compact as a whole.

[0030] like Figure 1 and Figure 2 As shown, the edge of the electrode plate body 100, which is fixed to the connecting terminal, is formed with an overlap groove 110. The depth and width of the overlap groove 110 are adapted to the overlap area of ​​the connecting terminal 200. One end of the connecting terminal 200 is embedded in the overlap groove 110, forming a surface contact overlap with the electrode plate body 100. The overlap area is 25 mm², and the fixing is achieved by friction stir welding. The shear strength of the joint after welding is high. In addition, the electrode plate body 100 is provided with electrode holes 120 for installing the capacitor core. The insulating plate 300 is provided with through holes corresponding to the electrode holes 120. This ensures that the capacitor core electrode can pass smoothly through the insulating plate and connect to the electrode holes 120 of the electrode plate body 100, and that there is no interference between the insulating plate and the capacitor core.

[0031] Example 2

[0032] This embodiment provides a processing technology for the laminated busbar electrode assembly in Embodiment 1, which improves the production efficiency and quality of the laminated busbar electrode assembly; specifically, it includes the following steps;

[0033] Step 1. Parts Machining: The aluminum and copper plates are processed into parts of acceptable product dimensions according to the design specifications of the electrode body and connecting terminals. In actual machining, the electrode body and connecting terminals are formed by laser cutting or stamping. After machining, the mating and overlapping surfaces of the connecting terminals can be polished to ensure a good fit during welding.

[0034] Step 2. Clamping and Positioning: Use specialized tooling fixtures for positioning and fixing. This involves using the fixtures to overlap or butt-fit the electrode plate body and connecting terminal parts at the welding station. During fixing, the connecting terminal is positioned and fixed according to its shape, while the electrode plate body is fixed through its internal holes. Ensure that the overlap / butt-fitting position deviation between the connecting terminal and the electrode plate body is ≤0.1mm. When the electrode plate body overlaps with the connecting terminal, the overlap area is not less than 20mm. 2 When the electrode body is mated with the connecting terminal, the mating gap between the electrode body and the connecting terminal is less than 0.3mm.

[0035] Step 3. Welding: Weld the lap and butt joint areas using friction stir welding. When lapping the electrode body with the connecting terminal, the welding head speed is 2600-3200 r / min, and the feed rate is 3-7 m / min, with preferred parameters being 3000 r / min and 5 m / min. When butt-jointing the electrode body with the connecting terminal, the welding head speed is 600-1000 r / min, and the feed rate is 3-7 m / min, with preferred parameters being 800 r / min and 5 m / min. The weld center is offset 0.5-2 mm from one side of the electrode body. This parameter design compensates for the thermal expansion difference between aluminum and copper, preventing weld cracking.

[0036] After welding is completed, the weld is visually inspected (to ensure there are no defects such as porosity, cracks, or incomplete penetration), and the internal quality is verified by ultrasonic testing. Then, the electrode plates and the insulating plates are stacked and assembled in sequence to form a complete stacked busbar electrode plate assembly.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

Claims

1. A laminated busbar electrode assembly, characterized in that; It includes multiple aluminum electrode bodies (100) arranged in layers, and each electrode body (100) is connected to several copper connecting terminals (200) at its edge. The electrode plate body (100) is fixed by overlapping or docking with the connecting terminal (200), and an insulating plate (300) is provided between adjacent electrode plate bodies (100).

2. The stacked busbar electrode assembly according to claim 1, characterized in that... ； The electrode body (100) located at the top and bottom layers is fixedly connected to the connecting terminal (200) of the layer. The electrode body (100) located between the bottom and bottom layers is fixedly connected to the connecting terminal (200) of the layer. The edge of the electrode body (100) fixedly connected to the connecting terminal (200) has an overlap groove (110).

3. The stacked busbar electrode assembly according to claim 1, characterized in that; The electrode plate body (100) and the connecting terminal (200) are fixed by welding after overlapping or butting, and the weld seam is in the form of a straight line or a curve.

4. The stacked busbar electrode assembly according to claim 1, characterized in that; The electrode plate body (100) is provided with electrode holes (120) for installing capacitor cores, and the insulating plate (300) is provided with through holes in the area corresponding to the electrode holes (120).

5. A processing technology for a laminated busbar electrode assembly, characterized in that, Includes the following steps; S1. Parts processing: The aluminum plate and copper plate raw materials are processed into parts of qualified product size according to the design specifications of the electrode body and the connecting terminal, respectively. S2. Clamping and positioning: Use tooling fixtures to fix the electrode body and connecting terminal parts by overlapping or butting them together at the welding station. During fixing, the connecting terminal is positioned and fixed according to the shape, and the electrode body is fixed through the inner hole. S3. Welding, which involves welding the lap and butt joint areas using friction stir welding.

6. The processing technology of the stacked busbar electrode assembly according to claim 5, characterized in that... ； In S1, the electrode body and the connecting terminal are formed by laser cutting or stamping.

7. The processing technology of the stacked busbar electrode assembly according to claim 5, characterized in that... ； In S2, when the electrode plate body overlaps with the connecting terminal, the overlapping area is not less than 20mm. 2 .

8. The processing technology of the stacked busbar electrode assembly according to claim 5, characterized in that... ； In S2, when the electrode body is mated with the connecting terminal, the mating gap between the electrode body and the connecting terminal is less than 0.3mm.

9. The processing technology of the laminated busbar electrode assembly according to claim 5, characterized in that... ； In S3, when the electrode body is connected to the connecting terminal, the welding head rotates at 2600-3200 r / min and the feed speed is 3-7 m / min.

10. The processing technology of the stacked busbar electrode assembly according to claim 5, characterized in that... ； In S3, when the electrode body is connected to the connecting terminal, the welding head rotates at 600-1000 r / min, the feed speed is 3-7 m / min, and the center of the weld is offset to one side of the electrode body by 0.5-2 mm.

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