Megawatt-level ultrafast charging aluminum bar for new energy automobile and process of megawatt-level ultrafast charging aluminum bar

Abstract

The invention discloses a megawatt-level ultrafast charging aluminum bar for a new energy automobile and a process. The megawatt-level ultrafast charging aluminum bar comprises an aluminum bar connector, one end of the aluminum bar is electrically connected with the aluminum bar connector, and the other end of the aluminum bar is provided with a connecting part; the copper ring is in fusion connection with the connecting part; the copper foil shielding adhesive tape wraps the surface of the aluminum bar; the charging socket further comprises a sealing protection assembly, a fixed damping assembly and a DC charging socket shell connected with an external charging gun in a pluggable mode. The sealing protection assembly comprises an aluminum row rear cover, an aluminum row sealing ring and a charging seat rear cover; the DC charging seat shell is electrically connected with the copper ring through the DC terminal; the aluminum bar is used as a megawatt charging carrier to bear ultra-large current, the electrochemical corrosion problem of copper-to-aluminum is solved, the high-conductivity electroplating layer process is adopted to increase the conductivity, the bolt is used for locking to reduce the resistance, large-current charging is safer and more reliable, the copper foil shielding adhesive tape is used as the shielding layer, the shielding requirement is met, the cost is reduced, and the service life is prolonged. And a megawatt charging connection scheme is realized.

Description

Technical Field

[0001] This invention relates to charging aluminum busbars and their manufacturing processes, and more particularly to a megawatt-level ultrafast charging aluminum busbar for new energy vehicles and its manufacturing process. Background Technology

[0002] With the rapid development of electric vehicle technology, battery capacity has exceeded 100kWh and is approaching 200kWh. Megawatt-level (1000kW and above) ultra-fast charging, enabling "500km range with 5 minutes of charging," is becoming an inevitable trend. At this power level, the system operating current can reach 800A to 1500A, placing near-extreme demands on the current-carrying capacity, heat dissipation performance, lightweight design, and cost control of the conductive components in the entire high-voltage charging circuit. Currently, the industry commonly uses pure copper conductors in high-voltage, high-current paths due to their excellent conductivity. However, when applied to megawatt-level systems, pure copper suffers from disadvantages such as high density, heavy weight, and high cost, hindering overall vehicle lightweighting and cost control.

[0003] In contrast, aluminum conductors, with a density only 30% that of copper, raw material costs approximately one-third to one-half that of copper, and abundant resources, are ideal alternative materials. However, directly applying aluminum conductors to high-voltage charging circuits for new energy vehicles, especially in megawatt-level scenarios, still faces technical bottlenecks. First, aluminum itself has lower conductivity than copper, resulting in more significant conduction losses and temperature rise under high current. Second, aluminum surfaces are prone to oxidation, and the oxide layer can increase contact resistance and cause localized overheating. Furthermore, when aluminum conductors must be electrically connected to the inherent copper terminals in charging interfaces and other components, a significant potential difference exists between the two, leading to severe electrochemical corrosion in humid environments, affecting the long-term reliability and safety of the connection point. In addition, differences in the coefficient of thermal expansion at the connection point, stress relaxation, and strong electromagnetic interference (EMI) radiation generated under high-current pulses also constitute major obstacles.

[0004] Existing solutions often only address single problems, such as using expensive special coatings or complex sealing structures. It is difficult to balance cost, process complexity, and long-term reliability. There is a lack of a systematic and cost-effective solution that covers materials, connections, shielding, and integrated fixation.

[0005] Therefore, the industry urgently needs an innovative technical solution that can systematically overcome the above-mentioned problems, enabling aluminum busbar conductors to stably, reliably, and economically carry the large current of megawatt-level ultra-fast charging. Summary of the Invention

[0006] To address the shortcomings of the aforementioned technologies, this invention provides a megawatt-level ultra-fast charging aluminum busbar and its manufacturing process for new energy vehicles.

[0007] To solve the above technical problems, the technical solution adopted by the present invention is: a megawatt-level ultra-fast charging aluminum busbar for new energy vehicles, including an aluminum busbar connector; An aluminum busbar, one end of which is electrically connected to an aluminum busbar connector, and the other end of which is machined with a connecting part; A copper ring, which is fused together with the connecting part by ultrasonic welding; Electromagnetic shielding is achieved by wrapping copper foil shielding tape around the surface of the aluminum busbar; It also includes a sealing and protective assembly, a fixing and shock-absorbing assembly, and a DC charging dock housing that is plugged into and connected to an external charging gun; The sealing and protection components include an aluminum busbar rear cover, an aluminum busbar sealing ring, and a charging base rear cover; The DC charging base housing is electrically connected to a copper ring via DC terminals located on it.

[0008] Furthermore, there can be multiple aluminum busbar connectors, all of which are wrapped together in copper foil shielding tape. The connecting part of the aluminum busbar connector is exposed outside the copper foil shielding tape. The connecting part is implemented by inserting it through the back cover of the aluminum busbar, and the connecting part has a through hole that matches the copper ring.

[0009] Furthermore, the aluminum busbar rear cover is snapped together with the charging base rear cover, and an aluminum busbar sealing ring is built into the two.

[0010] Furthermore, the back cover of the charging base has a connecting post that is coaxially corresponding to and passes through the inserted connecting part. A fastening bolt passes through the hole in the connecting post and is fastened by threading onto the DC terminal. A waterproof plug is fitted into the end of the fastening bolt and is fitted into the connecting post. An O-ring is provided on the outer surface of the side of the connecting post that is fitted into the DC terminal.

[0011] Furthermore, a grounding position is provided on the side of the DC charging base housing connected to the sealing and protection assembly. A grounding copper busbar is connected to the grounding position and secured by a grounding bolt. The free end of the grounding copper busbar is equipped with a grounding wire.

[0012] Furthermore, it also includes a charging dock bracket, through which the DC charging dock housing is mounted on the vehicle body.

[0013] Furthermore, the fixed shock absorption components include shock-absorbing rubber sleeves, sheet metal brackets, and cable ties; The vibration damping rubber sleeve is fitted onto the aluminum busbar that has been wrapped with copper foil shielding cloth; The sheet metal bracket is fitted onto the outer surface of the vibration damping rubber sleeve and secured by cable ties passing through pre-set mounting holes on the sheet metal bracket.

[0014] The manufacturing process for megawatt-level ultra-fast charging aluminum busbars for new energy vehicles includes the following steps: S1. The aluminum busbar is processed by a bending machine to form a preset bending angle, the PA insulation skin of the aluminum busbar is removed by a top-peeling machine, and a connecting part is formed at the exposed end of the aluminum busbar by a stamping die. S2. Ultrasonic welding is used to fuse the copper ring to the connecting part; S3. Wrap the copper foil shielding tape around the surface of the aluminum busbar; S4. Assemble the sealing and protection components, and assemble the aluminum busbar back cover, aluminum busbar sealing ring, charging base back cover, O-ring and waterproof plug into the corresponding positions in sequence; S5. Assemble the aluminum busbar assembly with copper ring to the DC terminal inside the DC charging base housing, and use fastening bolts to secure the copper ring to the DC terminal; S6. Install and fix the aluminum busbar using the fixed shock absorption components.

[0015] Furthermore, the copper ring in step S2 is made of T2 pure copper and its surface is processed with an electroplated nickel layer and an electroplated silver layer. In step S2, the ultrasonic welding equipment used is a welding head and welding seat with ring-shaped force-engaging protrusions to apply pressure to the edge of the copper ring and perform welding; the welding pressure is 0.55-0.60 MPa and the welding time is 2-3 seconds.

[0016] Furthermore, the copper foil shielding tape in step S3 is an integral structure formed by bonding T2 pure copper foil tape and cloth base tape with adhesive.

[0017] A megawatt-level ultrafast charging aluminum busbar and its process for new energy vehicles are disclosed. The aluminum busbar serves as the megawatt-level charging carrier, which can carry ultra-high current while solving the electrochemical corrosion problem of copper-to-aluminum conversion. A highly conductive electroplating process is used to increase conductivity, and a bolt-locking method is used to reduce resistance, making high-current charging safer and more reliable. Copper foil shielding tape is used as the shielding layer, which not only meets the shielding requirements but also reduces costs. This results in a superior alternative to traditional high-current charging carrier solutions, realizing a megawatt-level charging connection solution. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention.

[0019] Figure 2 This is an exploded view of the present invention.

[0020] In the diagram: 1. Aluminum busbar connector; 2. Aluminum busbar; 3. Vibration damping sleeve; 4. Sheet metal bracket; 5. Cable tie; 6. Copper foil shielding tape; 7. Connecting part; 8. Aluminum busbar back cover; 9. Aluminum busbar sealing ring; 10. Charging base back cover; 11. Connecting post; 12. Copper ring; 13. Fastening bolt; 14. Waterproof plug; 15. O-ring; 16. DC charging base housing; 17. DC terminal; 18. Grounding position; 19. Grounding bolt; 20. Grounding copper busbar; 21. Grounding wire; 22. Charging base bracket. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] like Figure 1-2 As shown in the figure, this embodiment relates to the aluminum busbar and process for megawatt-level ultra-fast charging of new energy vehicles, including an aluminum busbar connector 1 as the current input terminal and an aluminum busbar 2 as the main conductor.

[0023] In the processing, the aluminum busbar 2 is bent using a 3D bending machine. The 3D bending machine includes a feeding rack, a straightener, a wire feeding box, a coil forming unit, and a cutting unit. The aluminum busbar 2 is processed using pre-extruded coiled aluminum busbars. The busbars are loaded onto the feeding rack and fixed for feeding. The feeding rack's rollers are precisely fed using a servo motor. The feeding rack then feeds the aluminum busbars into the straightener, where straightening rollers straighten the busbars, creating a vertical conductor for bending. After straightening and straightening, the busbars are fed through the wire feeding box for dimension control. Pre-set parameters are input, interpreted by the computer as processing codes, and transmitted to the PLC industrial control system. The PLC industrial control system controls the servo motor rollers to precisely feed the aluminum busbars, achieving a dimensional accuracy within 0.5mm, ensuring precise feeding and dimensional precision. The bending process is controllable. The aluminum busbar is fed to the coiling and forming unit via a wire feeding box. The bending die is designed so that the tip radius of the upper die (punch) and the V-shaped opening width of the lower die (concave die) must match the thickness of the aluminum busbar. The mother busbar bending die usually has a cavity that matches the cross-sectional shape of the aluminum busbar, which can prevent deformation to the greatest extent. The aluminum busbar passes through the bending dies on the X, Y, and Z axes. According to the pre-set parameters, the equipment automatically adjusts the bending head die to perform plastic bending on the aluminum busbar, achieving precision control: horizontal bending angle: ±0.3 degrees, vertical bending ±0.5 degrees, torsion angle ±1.0 degrees, realizing precise dimensional forming of the aluminum busbar bending. After the coiling and forming unit bends the aluminum busbar according to the set parameters, the aluminum busbar passes through the fixed cutting blade on the cutting unit. The cutting blade cuts the aluminum busbar to the required size, and the aluminum busbar falls into the collection box. At this point, the bending process of the aluminum busbar is completed.

[0024] In the processing, an electromagnetic induction hot stripping machine is used to preheat the bent aluminum busbar to soften the PA material of the outer insulation layer of the aluminum busbar. After the PA material is softened by preheating, a top-removal stripping machine is used to remove the PA insulation layer of the aluminum busbar according to the required size, exposing the complete aluminum busbar carrier. Then, a customized size stamping die is used to punch the exposed part of the aluminum busbar into the required shape and size according to the requirements, completing the aluminum busbar shaping step, and thus forming the aluminum busbar 2 with the connecting part 7 required in this embodiment.

[0025] In this embodiment, to achieve a reliable connection between the aluminum conductor and the copper components in the charging system, a copper ring 12 is used as the transition component. The copper ring 12 is fused to the connection part 7 of the aluminum busbar 2 through an ultrasonic welding process. The integral welding does not require much consideration for waterproofing and moisture protection, which not only ensures that the aluminum will not loosen due to thermal expansion, but also solves the problems of creep and stress relaxation. In this process, the two metals form a metallurgical bond at the interface, fundamentally eliminating the potential difference at the copper-aluminum contact surface, thereby solving the problem of electrochemical corrosion, while ensuring connection strength and long-term stability.

[0026] The copper ring 12 is made of T2 pure copper and its surface is processed with an electroplated nickel layer and an electroplated silver layer. The processing sequence is to first perform an electroplated nickel layer treatment to increase the oxidation resistance, and then perform an electroplated silver layer treatment to increase the conductivity. The electroplated layers can effectively protect the copper ring 12 from corrosion caused by the external environment.

[0027] For the ultrasonic welding process of the connecting part 7 of aluminum busbar 2 and copper ring 12, the ultrasonic welding equipment used is a welding head and welding seat with ring-shaped force-engaging protrusions to apply pressure to the edge of copper ring 12 and perform welding; the welding pressure is 0.55-0.60 MPa, and the welding time is 2-3 seconds. It should be noted that the welding head with ring-shaped force-engaging protrusions meets the welding requirements while reducing energy loss to less than 5%, improving welding reliability by 30%, and solving the problem of pressure damage in the welding conductive area; it should be noted that the ultrasonic welding equipment used in this embodiment is model CX-20WD-13 (Bendingvibration machine, 13KW), frequency: 20KHz, transducer: N33 (N51) 13.6KW.

[0028] To address the strong electromagnetic interference generated during megawatt-level high-current charging, this embodiment wraps the surface of the aluminum busbar 2 with copper foil shielding tape 6. The copper foil shielding tape 6 is used to absorb and isolate electromagnetic radiation. It should be noted that the copper foil shielding tape 6 is made of T2 pure copper, which is rolled into copper foil strips. The copper foil strips are mixed with cloth base tape and glue and woven into copper foil shielding tape. The advantage is that the copper foil has a conductivity of 100% IACS, which effectively prevents interference energy from being radiated. At the same time, the cloth base tape is added to the surface for protection. The tape is integrally formed, and the tape can be wrapped once to meet the shielding and protection requirements, simplifying the tape wrapping process, making processing convenient, saving processing time, and reducing labor costs.

[0029] The electrical connection area of ​​the connection part 7 is covered by a sealing and protective component, which includes an aluminum busbar back cover 8, an aluminum busbar sealing ring 9, and a charging base back cover 10. These components together form a dustproof and moisture-proof barrier. The external charging interface of the device is provided through the DC charging base housing 16. The DC charging base housing 16 is plugged and plugged into the external charging gun. The DC charging base housing 16 forms a final electrical connection with the copper ring 12 through the DC terminal 17 provided on it, thereby completing the current path from the battery pack to the charging interface.

[0030] In actual manufacturing, the number of aluminum busbar connectors 1 can be set to multiple according to the specific configuration of the battery pack. The aluminum busbar 2 is wrapped in the shielding layer formed by the copper foil shielding cloth 6, but the connecting part 7 at the end of the aluminum busbar 2 is exposed outside the copper foil shielding cloth 6 and extends through the aluminum busbar back cover 8; such as Figure 2 As shown, the connecting part 7 has a through hole for fitting and installing with the copper ring 12. The aluminum busbar rear cover 8 and the charging base rear cover 10 are connected and fixed by a snap-fit ​​method. An aluminum busbar sealing ring 9 is provided between the two to ensure the sealing of the interface. The charging base back cover 10 has an integrally formed connecting post 11. When the connecting part 7 of the aluminum busbar 2 is inserted into place, the connecting post 11 and the through hole on the connecting part 7 are kept coaxial. The fastening bolt 13 passes through the through hole on the connecting post 11 and the connecting part 7 in sequence, and finally screws into the threaded hole of the DC terminal 17 inside the DC charging base housing 16, thereby firmly pressing the copper ring 12 onto the contact surface of the DC terminal 17 to form an electrical connection. On this basis, in order to ensure long-term sealing, a waterproof plug 14 is inserted at the end of the fastening bolt 13 to seal the bolt through hole. At the same time, an O-ring 15 is fitted on the outer ring of the end where the connecting post 11 fits into the DC charging base housing 16 to further improve the sealing performance. It should be noted that the charging base back cover 10 is injection molded from PA66-20GF nylon and glass fiber material, which is lightweight, has high shell strength, and good insulation performance. It should also be noted that the aluminum busbar sealing ring 9, waterproof plug 14, and O-ring 15 are all injection molded from VQM silicone rubber material. VQM silicone rubber material has high and low temperature resistance, chemical stability, and electrical insulation. Its working temperature range is -60℃ to 300℃. It can withstand the high temperature aging generated during aluminum busbar charging, and long-term use at high temperatures will not affect the sealing performance.

[0031] On the side of the DC charging base housing 16 facing the sealing and protection assembly, a dedicated grounding position 18 is machined. A grounding copper busbar 20 is fastened to this grounding position 18 by a grounding bolt 19, and the free end of the grounding copper busbar 20 is connected to a grounding wire 21. The other end of the grounding wire 21 is electrically connected to the copper foil shielding cloth 6 wrapped around the aluminum busbar 2, thereby providing a discharge path for the electromagnetic interference energy absorbed by the copper foil shielding cloth 6 and effectively suppressing electromagnetic radiation.

[0032] The entire DC charging base housing 16 is mounted and fixed to a suitable position on the vehicle body via an independent charging base bracket 22.

[0033] To adapt to the vibration environment during vehicle operation, the aluminum busbar 2 is fixed and damped in the vehicle body, including a fixed damping component. The fixed damping component specifically includes a damping rubber sleeve 3, a sheet metal bracket 4, and cable ties 5. During assembly, the damping rubber sleeve 3 is first placed around the aluminum busbar 2, which has been wrapped with copper foil shielding cloth 6. Then, the sheet metal bracket 4 is fitted around the damping rubber sleeve 3. Finally, the cable ties 5 are passed through the pre-set mounting holes on the sheet metal bracket 4 for binding and fastening. This structure avoids the risk of the aluminum busbar 2 breaking due to long-term vibration fatigue or stress concentration, taking into account both reliability and economy.

[0034] The process in this embodiment can be summarized as follows: First, the aluminum busbar 2 is formed and its ends are prepared. That is, the aluminum busbar 2 is processed into a preset wiring path and angle by a bending machine. Then, the PA insulation skin of a predetermined length at the end is removed by a top-removing peeling machine. Finally, a regular-shaped connecting part 7 is processed on the exposed aluminum end by a special stamping die. A copper ring 12 with a surface treated with electroplated nickel and electroplated silver layers is used. An ultrasonic welding device is used to apply a pressure of 0.55 to 0.60 MPa to the edge of the copper ring 12 with a special welding head and welding seat designed with ring-shaped force-engaging protrusions. Within a welding time of 2 to 3 seconds, it is fused and connected to the connecting part 7 of the aluminum busbar 2 into one piece. Next, electromagnetic shielding is performed by wrapping the copper foil shielding tape 6 around the surface of the aluminum busbar 2. Then assemble the sealing and protection components, and install the aluminum busbar back cover 8, aluminum busbar sealing ring 9, charging base back cover 10, O-ring 15 and waterproof plug 14 in the designated positions in sequence. Then assemble the charging interface, align the aluminum busbar assembly with the copper ring 12 welded on with the DC terminal 17 in the DC charging base housing 16, and use the fastening bolts 13 to complete the fastening connection.

[0035] Finally, the entire vehicle is integrated and fixed by inserting the aluminum strip 2 into the damping rubber sleeve 3 that has been pressed into the sheet metal bracket 4, and then using cable ties 5 to tie it tightly, thus completing the installation of the entire aluminum strip on the vehicle body.

[0036] This application discloses a megawatt-level ultra-fast charging aluminum busbar and its process for new energy vehicles. The aluminum busbar is used as a megawatt-level charging carrier, which can carry ultra-high current while solving the electrochemical corrosion problem of copper-to-aluminum conversion. A high-conductivity electroplating process is used to increase conductivity, and a bolt locking method is used to reduce resistance, making high-current charging safer and more reliable. Copper foil shielding tape is used as a shielding layer, which not only meets the shielding requirements but also reduces costs. This provides a superior alternative to traditional high-current charging carrier solutions, realizing a megawatt-level charging connection solution.

[0037] The above embodiments are not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the technical solution of the present invention are also within the protection scope of the present invention.

Claims

1. A megawatt-level ultra-fast charging aluminum busbar and its process for new energy vehicles, characterized in that: include, Aluminum busbar connector (1); An aluminum busbar (2) has one end electrically connected to the aluminum busbar connector (1) and the other end is machined with a connecting part (7). A copper ring (12) is fused to the connecting part (7) by ultrasonic welding; Copper foil shielding tape (6) is used to provide electromagnetic shielding by wrapping it around the surface of the aluminum busbar (2); It also includes a sealing and protection component, a fixing and shock-absorbing component, and a DC charging base housing (16) that is plugged into and connected to an external charging gun. The sealing and protection assembly includes an aluminum busbar rear cover (8), an aluminum busbar sealing ring (9), and a charging base rear cover (10). The DC charging base housing (16) is electrically connected to the copper ring (12) through the DC terminal (17) disposed thereon.

2. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 1, characterized in that: The number of aluminum busbar connectors (1) can be multiple. Multiple aluminum busbar connectors (1) are wrapped together in copper foil shielding cloth (6). The connecting part (7) of the aluminum busbar connector (1) is exposed outside the copper foil shielding cloth (6). The connecting part (7) is implemented by inserting through the aluminum busbar back cover (8). The connecting part (7) has a through hole that matches the copper ring (12).

3. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 1, characterized in that: The aluminum busbar rear cover (8) is snapped together with the charging base rear cover (10), and an aluminum busbar sealing ring (9) is built between them.

4. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 2, characterized in that: The charging base back cover (10) has a connecting post (11) that is coaxially corresponding to and passes through the inserted connecting part (7). A fastening bolt (13) that passes through the hole in the connecting part (7) passes through the connecting post (11). The fastening bolt (13) is fastened to the DC terminal (17) by means of threaded connection. A waterproof plug (14) is fitted into the end of the fastening bolt (13) and is fitted into the connecting post (11). An O-ring (15) is provided on the outer surface of the connecting post (11) and the DC terminal (17) on the side where they are fitted and connected.

5. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 1, characterized in that: The DC charging base housing (16) has a grounding position (18) on the side of the housing connected to the sealing and protection component. A grounding copper busbar (20) is connected to the grounding position (18) and fastened by a grounding bolt (19). The free end of the grounding copper busbar (20) is equipped with a grounding wire (21).

6. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 1, characterized in that: It also includes a charging base bracket (22), through which the DC charging base housing (16) is mounted on the vehicle body.

7. The megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 1, characterized in that: The fixed shock absorption assembly includes a shock-absorbing rubber sleeve (3), a sheet metal bracket (4), and cable ties (5); The vibration damping rubber sleeve (3) is looped around the aluminum busbar (2) which has been wrapped with copper foil shielding cloth (6); The sheet metal bracket (4) is fitted onto the outer surface of the vibration damping sleeve (3) and is secured by cable ties (5) passing through the pre-set mounting holes on the sheet metal bracket (4).

8. The process for the megawatt-level ultra-fast charging aluminum busbar for new energy vehicles as described in any one of claims 1-7, characterized in that, Includes the following steps: S1. The aluminum strip (2) is processed by a bending machine to form a preset bending angle. The PA insulation skin of the aluminum strip (2) is removed by a top-removing peeling machine. A connecting part (7) is formed at the exposed end of the aluminum strip (2) by a stamping die. S2. Ultrasonic welding is used to fuse the copper ring (12) to the connecting part (7); S3. Wrap the copper foil shielding tape (6) around the surface of the aluminum busbar (2); S4. Assemble the sealing and protection components, and assemble the aluminum busbar back cover (8), aluminum busbar sealing ring (9), charging base back cover (10), O-ring (15) and waterproof plug (14) into the corresponding positions in sequence; S5. Assemble the aluminum busbar assembly with copper ring (12) with the DC terminal (17) inside the DC charging base housing (16), and fasten the copper ring (12) and the DC terminal (17) with fastening bolts (13); S6. Install and fix the aluminum busbar (2) by fixing the shock absorption components.

9. The process for the megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 8, characterized in that: The copper ring (12) in step S2 is made of T2 pure copper and its surface is processed with an electroplated nickel layer and an electroplated silver layer. The ultrasonic welding equipment used in step S2 is a welding head and welding seat with ring-shaped force-engaging protrusions to apply pressure to the edge of the copper ring (12) and perform welding; the welding pressure is 0.55-0.60 MPa and the welding time is 2-3 seconds.

10. The process for the megawatt-level ultra-fast charging aluminum busbar for new energy vehicles according to claim 8, characterized in that: The copper foil shielding tape (6) in step S3 is an integral structure formed by bonding T2 pure copper foil tape and cloth base tape with adhesive.

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