Electrical connector, electrical component and electrical device

Abstract

The application belongs to the technical field of energy storage and provides an electric connecting piece, an electric element and an electric device. The electric connecting piece comprises a first connecting body, a second connecting body and a reaction layer. The base material of the second connecting body is different from the base material of the first connecting body, and the second connecting body and the first connecting body are arranged along a first direction. The reaction layer is formed by diffusion of the base material of the first connecting body and the base material of the second connecting body towards each other at a contact interface. The thickness of the reaction layer is a first thickness W1, the thickness of the one with smaller thickness in the first connecting body and the second connecting body is a second thickness W2, and the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 10% and less than or equal to 75%. The first connecting body and the second connecting body in the electric connecting piece provided by the application can have higher bonding strength, and the electric connecting piece has excellent electric conductivity.

Description

Technical Field

[0001] This application relates to the field of energy storage technology, and in particular to an electrical connector, electrical component and electrical equipment. Background Technology

[0002] In the electrical industry, electrical connectors are commonly used to connect two conductive components. The conductivity of these connectors plays a crucial role in the electrical industry's performance. Copper, with its advantages of low resistance and high conductivity, is widely used in electrical connectors. However, copper is expensive and dense, which hinders lightweight system design. Therefore, aluminum has been proposed as a substitute. However, aluminum has a significantly higher resistivity than copper. Directly using pure aluminum as a connector would lead to increased resistance and heat generation, affecting the stability and energy efficiency of electrical equipment.

[0003] To balance resistance and production costs, copper-aluminum composite connection technology has emerged. However, current composite connection technology cannot simultaneously address the structural strength and conductivity of electrical connectors. Summary of the Invention

[0004] This application provides an electrical connector, an electrical component, and an electrical device. The first and second connectors in the electrical connector can have high bonding strength, and the electrical connector has excellent conductivity.

[0005] This application provides an electrical connector, including a first connector, a second connector, and a reactive layer. The substrate of the second connector is different from the substrate of the first connector, and the second connector and the first connector are arranged along a first direction. The reactive layer is formed by diffusion of the substrates of the first connector and the substrates of the second connector toward each other at the contact interface. The thickness of the reactive layer is a first thickness W1, and the thickness of the smaller of the first connector and the second connector is a second thickness W2. The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 10% and less than or equal to 75%.

[0006] In one possible implementation, the electrical connector provided in this application has a first thickness W1 ratio to the sum of the first thickness W1 and the second thickness W2 that is greater than or equal to 15% and less than or equal to 70%.

[0007] In one possible implementation, the electrical connector provided in this application has a first thickness W1 ratio to the sum of the first thickness W1 and the second thickness W2 that is greater than or equal to 15% and less than or equal to 60%.

[0008] In one possible implementation, the electrical connector provided in this application has a first thickness W1 ratio to the sum of the first thickness W1 and the second thickness W2 that is greater than or equal to 25% and less than or equal to 60%.

[0009] In one possible implementation, the electrical connector provided in this application has at least one protrusion on one of the first connector and the second connector, and at least one recess on the other, with the at least one protrusion inserted into the at least one recess.

[0010] In one possible implementation, the electrical connector provided in this application has a first connector with a smaller coefficient of thermal expansion than a second connector, the first connector has at least one recess, and the second connector has at least one protrusion.

[0011] In one possible implementation, the electrical connector provided in this application includes a first connector body comprising a first bottom wall and a first side wall, the first side wall surrounding the periphery of the first bottom wall to form a recess; a protrusion having a second bottom wall and a second side wall; a reaction layer being formed between the first side wall and the second side wall, and a reaction layer being formed between the first bottom wall and the second bottom wall.

[0012] In one possible implementation, the electrical connector provided in this application has a first sidewall thickness of a second thickness W2, and the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 25% and less than or equal to 60%.

[0013] In one possible implementation, the electrical connector provided in this application has a reactive layer with a conductivity lower than that of the second connector, and a first connector with a conductivity higher than that of the second connector.

[0014] In one possible implementation, the electrical connector provided in this application has a reaction layer with a strength less than that of the second connector, and a first connector with a strength greater than that of the second connector.

[0015] In one possible implementation, the electrical connector provided in this application has a first connector substrate comprising copper and its alloys; and / or a second connector substrate comprising aluminum and its alloys.

[0016] This application also provides an electrical component, including the aforementioned electrical connector.

[0017] In one possible implementation, the electrical components provided in this application are relays, transformers, fuses, busbars, heat sinks, or printed circuit boards.

[0018] In one possible implementation, the electrical component provided in this application is a relay, and the electrical connector is a composite contact of the relay; the relay also includes a housing, the composite contact is connected to the housing, and the composite contact is inserted into the housing.

[0019] In one possible implementation, the electrical component provided in this application, the relay, further includes a coil, a moving contact, and a moving armature disposed within a housing; the coil is sleeved outside the moving armature, the moving armature is connected to the moving contact via a transmission connection, and when the coil is energized, it drives the moving armature to cause the moving contact to connect or disconnect with the composite contact.

[0020] This application also provides an electrical device that includes the above-mentioned electrical connector or electrical components.

[0021] The electrical connector provided in this application comprises a first connector, a second connector, and a reaction layer. The substrate of the second connector is different from that of the first connector, and the second and first connectors are arranged along a first direction. The reaction layer is formed by the diffusion of the substrates of the first and second connectors towards each other at the contact interface. The reaction layer, formed by the diffusion of the substrates of the first and second connectors towards each other, has high bonding strength with both the first and second connectors, resulting in a high bonding strength between the first and second connectors. The first and second connectors can be bonded through the reaction layer, which prevents direct contact between them, thereby avoiding a galvanic cell effect and resulting in good electrical conductivity. The ratio of the thickness of the reaction layer to the minimum thickness of the first and second connectors at the contact interface can be controlled within a certain range to ensure both the reaction layer is neither too thin (ensuring connection strength) nor too thick (ensuring both conductivity and connection strength). Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of the electrical connector provided in the embodiments of this application;

[0024] Figure 2 This is another structural schematic diagram of the electrical connector provided in the embodiments of this application;

[0025] Figure 3 for Figure 1 A schematic diagram of the structure of the second connector in the electrical connector shown;

[0026] Figure 4 for Figure 1 A schematic diagram of the structure of the first connector in the electrical connector shown;

[0027] Figure 5 This is a schematic diagram of the structure of a relay provided in an embodiment of this application;

[0028] Figure 6 The curve showing the relationship between resistance value and reaction layer thickness in the electrical connector provided in the embodiments of this application;

[0029] Figure 7 The curve showing the relationship between bonding strength and reactive layer thickness in the electrical connector provided in the embodiments of this application;

[0030] Figure 8 Scan result image of embodiment 1 of the electrical connector provided in this application;

[0031] Figure 9 Scan result image of embodiment 3 of the electrical connector provided in this application;

[0032] Figure 10 Scan result image of embodiment 4 of the electrical connector provided in this application;

[0033] Figure 11 Scan result image of embodiment 5 of the electrical connector provided in this application;

[0034] Figure 12 Scan result image of embodiment 6 of the electrical connector provided in this application;

[0035] Figure 13 Scan result image of embodiment 7 of the electrical connector provided in this application;

[0036] Figure 14 Scan result image of embodiment 8 of the electrical connector provided in this application;

[0037] Figure 15 Scan result image of embodiment 9 of the electrical connector provided in this application;

[0038] Figure 16 A scanned image of the electrical connector of embodiment 10 provided in this application;

[0039] Figure 17 A scan result image of embodiment 11 of the electrical connector provided in this application;

[0040] Figure 18 Scan result image of embodiment 12 of the electrical connector provided in this application;

[0041] Figure 19 Scan result image of embodiment 13 of the electrical connector provided in this application;

[0042] Figure 20 A scan result diagram of embodiment 14 of the electrical connector provided in this application.

[0043] Explanation of reference numerals in the attached figures:

[0044] 10-Relay;

[0045] 100 - Electrical connectors;

[0046] 110 - First connecting body; 111 - Recessed portion; 112 - First bottom wall; 113 - First side wall;

[0047] 120 - Second connecting body; 121 - Protrusion; 122 - Second bottom wall; 123 - Second side wall;

[0048] 130 - Reaction layer;

[0049] 200 - Housing; 210 - First housing; 220 - Second housing; 230 - Support plate; 240 - Sleeve; 250 - Connecting platform;

[0050] 300-coil;

[0051] 400-Moving contact;

[0052] 500 - Moving armature; 510 - Mandrel;

[0053] 20-Adapter;

[0054] W1 - First thickness; W2 - Second thickness;

[0055] X - First direction. Detailed Implementation

[0056] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0057] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, an indirect connection through an intermediate medium, or the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0058] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0059] The terms "first," "second," and "third" in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein.

[0060] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion, such as a process, method, system, product, or maintenance tool that includes a series of steps or units, not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or maintenance tool.

[0061] In the electrical industry, electrical connectors are commonly used to connect two conductive components. The conductivity of these connectors plays a crucial role in the electrical industry's performance. Copper, with its advantages of low resistance and high conductivity, is widely used in electrical connectors. However, copper is expensive and dense, which hinders lightweight system design. Therefore, aluminum has been proposed as a substitute. However, aluminum has a significantly higher resistivity than copper. Directly using pure aluminum as a connector would lead to increased resistance and heat generation, affecting the stability and energy efficiency of electrical equipment.

[0062] To balance resistance and production costs, copper-aluminum composite connection technology has emerged. Specifically, the electrical connector includes copper and aluminum components, which are then connected together. The bonding strength between the copper and aluminum components at the connection point is relatively low. The end of the aluminum component facing away from the copper component is fixed to the aluminum busbar with bolts; bolted connections have low torsional resistance. During long-term use, the different coefficients of thermal expansion of the copper and aluminum components cause the connection to loosen, increasing contact resistance and consequently reducing conductivity. Furthermore, the galvanic effect and potential difference corrosion between the copper and aluminum components can lead to poor contact, overheating, sparking, and increased resistance at the connection point.

[0063] The galvanic cell effect refers to the formation of an electrolyte at the contact surface of two metals with different conductivity under the influence of moisture, carbon dioxide, and other impurities in the air. This creates a galvanic cell with the metal with lower conductivity as the negative electrode and the metal with higher conductivity as the positive electrode, generating current and driving a redox reaction that corrodes the contact surface between the two metals. Potential difference corrosion of copper and aluminum refers to the phenomenon where, when copper and aluminum are in direct contact in an electrolyte, the potential difference forms a galvanic cell, accelerating the corrosion of the copper.

[0064] Based on this, embodiments of this application provide an electrical connector, an electrical component, and an electrical device. The first connector and the second connector in the electrical connector can have high bonding strength, and the electrical connector has excellent conductivity.

[0065] Figure 1 This is a schematic diagram of the structure of the electrical connector provided in the embodiments of this application; Figure 2 This is another structural schematic diagram of the electrical connector provided in the embodiments of this application; Figure 3 for Figure 1 A schematic diagram of the structure of the second connector in the electrical connector shown; Figure 4 for Figure 1 The diagram shows the structure of the first connector in the electrical connector.

[0066] See Figures 1 to 4 As shown, the electrical connector 100 includes a first connector 110, a second connector 120, and a reactive layer 130. The substrate of the second connector 120 is different from that of the first connector 110. The second connector 120 and the first connector 110 are arranged along a first direction X. The reactive layer 130 is formed by the diffusion of the substrates of the first connector 110 and the second connector 120 towards each other at the contact interface. The thickness of the reactive layer 130 is a first thickness W1, and the minimum thickness of the first connector 110 and the second connector 120 in the region where the reactive layer 130 is formed is a second thickness W2. The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 10% and less than or equal to 75%.

[0067] The first connector 110 and the second connector 120 can be columnar or plate-shaped components. The first connector 110 and the second connector 120 are arranged in a first direction X. The ends of the first connector 110 and the second connector 120 facing each other are connected. The end of the first connector 110 away from the second connector 120 is connected to other devices. The end of the second connector 120 away from the first connector 110 is connected to another device. Thus, two devices can be connected through the first connector 110 and the second connector 120.

[0068] The first connector 110 and the second connector 120 have different base materials. For example, the base material of the first connector 110 can be copper or a copper alloy. Copper has high conductivity, high weight per unit area, and high strength; however, copper is also more expensive. The base material of the second connector 120 can be aluminum or an aluminum alloy. Aluminum has slightly lower conductivity than copper, lower weight per unit area, and lower strength; however, aluminum is also less expensive. By combining the first connector 110 and the second connector 120, the electrical connector 100 can reduce weight and cost without significantly affecting its conductivity.

[0069] The first connector 110 and the second connector 120 can be joined by diffusion welding. Diffusion welding is a solid-state welding technology that uses the combined action of high temperature and pressure to achieve metallurgical bonding between contacting metal substrates based on atomic diffusion, without melting the substrate.

[0070] Specifically, when connecting the first connector 110 and the second connector 120, the first connector 110 and the second connector 120 are placed at a certain temperature, and a certain pressure is applied to the first connector 110 and the second connector 120 along a first direction X. The substrates of the first connector 110 and the second connector 120 are in contact for an appropriate time, so that the substrates of the first connector 110 and the second connector 120 diffuse towards each other. A reaction layer 130 is formed at the contact interface of the first connector 110 and the second connector 120.

[0071] The substrates of the first connector 110 and the second connector 120 diffuse toward each other to form a reaction layer 130. The reaction layer 130 has a high bonding strength with both the first connector 110 and the second connector 120, so that the first connector 110 and the second connector 120 can have a high bonding strength.

[0072] The first connector 110 and the second connector 120 can be bonded together through the reactive layer 130. The reactive layer 130 prevents the first connector 110 and the second connector 120 from directly contacting each other, thereby avoiding the formation of a galvanic cell effect between the first connector 110 and the second connector 120, resulting in better conductivity of the electrical connector 100. Furthermore, since the reactive layer 130 does not introduce new materials, there are fewer uncontrollable factors affecting the strength and conductivity of the electrical connector 100, making it easier to specifically improve strength and conductivity.

[0073] The substrate of the reaction layer 130 will be described using copper as the substrate of the first connector 110 and aluminum as the substrate of the second connector 120. During the diffusion bonding process of the first connector 110 and the second connector 120, copper diffuses towards the second connector 120, and aluminum diffuses towards the first connector 110, forming a copper-aluminum alloy of various compositions in the reaction layer 130. These copper-aluminum alloys are relatively brittle and have low electrical resistance, resulting in a reaction layer 130 with low strength and high electrical resistance.

[0074] The thickness of the reaction layer 130 is a first thickness W1, and the minimum thickness of the first connector 110 and the second connector 120 in the region where the reaction layer 130 is formed is a second thickness W2.

[0075] It should be noted that the cross-sections of the first connecting body 110 and the second connecting body 120 can be regular or irregular shapes. Figure 2 In the illustrated embodiment, the first connector 110 and the second connector 120 have regular cross-sectional shapes, and their entire surfaces facing each other are in contact. The dimension of the first connector 110 along the first direction X is its thickness, and the dimension of the second connector 120 along the first direction X is its thickness. The minimum thickness of the first connector 110 and the second connector 120 in the region forming the reaction layer 130 is the thickness of the first connector 110.

[0076] exist Figure 1 In the illustrated embodiment, the cross-sections of the first connector 110 and the second connector 120 are irregularly shaped, and the portion of the surface of the second connector 120 facing the first connector 110 is in contact with the first connector 110. The minimum thickness of the first connector 110 and the second connector 120 in the region forming the reaction layer 130 refers to: the minimum dimension of the first connector 110 in the projection region of the reaction layer 130 facing the location of the first connector 110 is the first minimum thickness, the minimum dimension of the second connector 120 in the projection region of the reaction layer 130 facing the location of the second connector 120 is the second minimum thickness, and the smaller of the first minimum thickness and the second minimum thickness is the second thickness W2.

[0077] When the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is small, the substrates of the first connector 110 and the second connector 120 do not diffuse sufficiently toward each other, resulting in a lower bonding strength between the first connector 110 and the second connector 120, and consequently a lower overall strength of the electrical connector 100.

[0078] The conductivity of the reaction layer 130 is lower than that of the second connector 120. The reaction layer 130 is composed of a multiphase mixture with a high grain boundary density, making it prone to vacancies and dislocation layer defects. These defects hinder electron migration, resulting in a higher resistance and lower conductivity in the reaction layer 130. When the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is too large, the overall conductivity of the electrical connector 100 is poor. The copper-aluminum alloy in the reaction layer 130 is brittle and easily becomes a crack initiation point, causing the strength of the reaction layer 130 to be lower than that of the second connector 120. Therefore, an excessively large thickness of the reaction layer 130 also results in lower overall strength of the electrical connector 100.

[0079] The ratio P of the first thickness W1 to the second thickness W2 can be expressed by the following formula:

[0080] P = W1 / (W1+W2)) × 100%.

[0081] When the ratio P is 10%, the measured resistance of electrical connector 100 is approximately 0.0303 mΩ; when the ratio P is 75%, the measured resistance of electrical connector 100 is approximately 0.1638 mΩ. When the ratio P is 10%, the measured bond strength of the first connector 110 and the second connector 120 is approximately 20.11 MPa; when the ratio P is 70%, the measured bond strength of the first connector 110 and the second connector 120 is approximately 20.36 MPa. The bond strength of the first connector 110 and the second connector 120 reflects the tensile strength of electrical connector 100.

[0082] Therefore, by controlling process parameters such as temperature, time, and pressure in diffusion welding, the ratio P can be made greater than or equal to 10% and less than or equal to 75%. This results in a resistivity of reaction layer 130 less than or equal to 0.164 mΩ and a bond strength greater than 20 MPa. Given that the tensile strength of aluminum is approximately 28-35 MPa, the bond strength between the first connector 110 and the second connector 120 is approximately 60% of the tensile strength of aluminum, close to the tensile strength of pure aluminum, resulting in high strength for the electrical connector 100. For example, the ratio P can be 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, etc.

[0083] Furthermore, by constraining the relationship between the thickness of the reaction layer 130 and the thickness of the first connector 110 or the second connector 120 through the ratio P of the first thickness W1 to the second thickness W2, the thickness of the reaction layer 130 can be set according to the size of the first connector 110 or the size of the second connector 120, so that the reaction layer 130 can reliably connect the first connector 110 and the second connector 120, avoiding the reaction layer 130 being too thick or too thin.

[0084] In one possible implementation, the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 15% and less than or equal to 70%.

[0085] When the ratio P is 15%, the measured resistance of electrical connector 100 is approximately 0.045 mΩ; when the ratio P is 70%, the measured resistance of electrical connector 100 is approximately 0.15 mΩ. When the ratio P is 15%, the measured bond strength of the first connector 110 and the second connector 120 is approximately 24.17 MPa; when the ratio P is 70%, the measured bond strength of the first connector 110 and the second connector 120 is approximately 24.02 MPa. The bond strength of the first connector 110 and the second connector 120 is greater than 24 MPa (approximately 80% of the tensile strength of aluminum), which is closer to the tensile strength of pure aluminum, resulting in higher strength of electrical connector 100. By making the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 greater than or equal to 15% and less than or equal to 70%, the resistance of electrical connector 100 can be further reduced, and the bond strength of the first connector 110 and the second connector 120 can be further increased.

[0086] In one possible implementation, the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 15% and less than or equal to 60%.

[0087] When the ratio P is 60%, the measured resistance of electrical connector 100 is 0.1256 mΩ, and the measured bond strength of the first connector 110 and the second connector 120 is 28.03 MPa. Compared to a ratio P of 70%, a ratio P of 60% reduces the resistance of the electrical connector by approximately 0.025 mΩ and increases the bond strength by approximately 4 MPa. Therefore, by controlling process parameters such as temperature, time, and pressure in diffusion welding, the upper limit of the ratio P can be reduced to a value greater than or equal to 15% and less than or equal to 60%, thereby further improving the strength and conductivity of electrical connector 100.

[0088] In one possible implementation, the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 25% and less than or equal to 60%.

[0089] When the ratio P is 25%, the measured resistance of the electrical connector 100 is approximately 0.061 mΩ, and the measured bonding strength of the first connector 110 and the second connector 120 is 28.23 MPa. Compared to a ratio P of 15%, a ratio P of 25% only increases the resistance of the electrical connector 100 by 0.045 mΩ, but increases the strength by approximately 4 MPa. Therefore, by increasing the lower limit of the ratio P from 15% to 25%, the strength of the electrical connector 100 can be further increased with minimal impact on its conductivity.

[0090] Please continue reading Figure 1 , Figure 3 and Figure 4 As shown, in one possible embodiment, one of the first connector 110 and the second connector 120 has at least one protrusion 121 and the other has at least one recess 111, with the at least one protrusion 121 inserted into the at least one recess 111.

[0091] The protrusion 121 can be one or more, in Figure 1 and Figure 3 A protrusion 121 is schematically shown. A recess 111 is provided in a one-to-one correspondence with the protrusion 121, with the protrusion 121 inserted into the corresponding recess 111. It is understood that the contour of the outer surface of the protrusion 121 completely fits the contour of the inner wall of the recess 111.

[0092] This configuration allows the first connector 110 and the second connector 120 to form an interlocking mechanism, increasing the contact area and mechanical strength at the connection point. Furthermore, the recess 111 and the protrusion 121 create a mechanical anchoring effect, further enhancing the mechanical engagement of the first connector 110 and the second connector 120, thereby improving shear resistance, tensile strength, and fatigue resistance. The cross-sectional shape of the protrusion 121 and the recess 111 can be circular, elliptical, rectangular, trapezoidal, semi-circular, semi-elliptical, etc. See other possible examples. Figure 2 As shown, the first connector 110 and the second connector 120 can also be connected in a planar manner, that is, the surfaces to be connected by the first connector 110 and the second connector 120 are both planar.

[0093] In one possible implementation, the coefficient of expansion of the first connector 110 is smaller than that of the second connector 120, the first connector 110 is provided with at least one recess 111, and the second connector 120 is provided with at least one protrusion 121.

[0094] The first connector 110 is made of copper, and the second connector 120 is made of aluminum. Copper has a smaller coefficient of thermal expansion than aluminum. A recess 111 is provided on the first connector 110, and a protrusion 121 is provided on the second connector 120. When the electrical connector 100 operates in a high-temperature environment, both the first connector 110 and the second connector 120 expand due to heat. The expansion of the protrusion 121 in the second connector 120 is greater than the expansion of the sidewall of the recess 111. This allows the protrusion 121 to exert a force on the sidewall of the recess 111, which increases the bonding strength between the first connector 110 and the second connector 120. Furthermore, aluminum is less expensive than copper. By providing the recess 111 on the first connector 110 and the protrusion 121 on the second connector 120, the amount of copper used is reduced, while the amount of aluminum used is increased, thus reducing the cost of the electrical connector 100.

[0095] The first connector 110 includes a first bottom wall 112 and a first side wall 113. The first side wall 113 surrounds the periphery of the first bottom wall 112 to form a recess 111. The protrusion 121 has a second bottom wall 122 and a second side wall 123. A reaction layer 130 is formed between the first side wall 113 and the second side wall 123, and a reaction layer 130 is formed between the first bottom wall 112 and the second bottom wall 122.

[0096] In other words, the outer wall of the protrusion 121 and the inner wall of the recess 111 are completely fitted together. As a result, a reaction layer 130 can be formed between the first side wall 113 of the recess 111 and the second side wall 123 of the protrusion 121, and a reaction layer 130 can also be formed between the first bottom wall 112 of the recess 111 and the second bottom wall 122 of the protrusion 121. This further increases the contact area between the first connector 110 and the second connector 120, and increases the bonding strength between the first connector 110 and the second connector 120.

[0097] The thickness of the first sidewall 113 is less than the thickness of the first bottom wall 112, and the thickness of the first sidewall 113 is also less than the size of the protrusion 121. Therefore, the thickness of the first sidewall 113 is the second thickness W2, and the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 25% and less than or equal to 60%. Because Figure 1 In the illustrated embodiment, the reaction layer 130 is formed over a larger area, and the strength of the first connector 110 and the second connector 120 is relatively reliable. Therefore, the range of the ratio P can be smaller, ensuring good electrical conductivity of the electrical connector 100 while maintaining bonding strength. For example, the ratio P is greater than or equal to 25% and less than or equal to 60%.

[0098] This application embodiment also provides an electrical component, which includes the above-described electrical connector 100.

[0099] The specific structure of the electrical connector 100 has been described in detail in the above embodiments and will not be repeated here. The electrical connector 100 is used to enable the connection or disconnection of two devices in an electrical component, so as to cooperate with other devices or mechanisms for operation, and has a wide range of applications in electrical components. Because the electrical component includes the electrical connector 100, the electrical component has the advantages of high strength and good conductivity.

[0100] The electrical components can be relays, transformers, fuses, busbars, heat sinks, or printed circuit boards. Each of these electrical components can perform a specific function and can work in conjunction with other structures.

[0101] The following uses a relay as an example to illustrate the specific structure of electrical components.

[0102] Figure 5 This is a schematic diagram of the structure of a relay provided in an embodiment of this application. Wherein, Figure 5 The adapter 20 connected to the relay 10 is also shown.

[0103] See Figure 5 As shown, the electrical connector 100 is a composite contact of the relay 10; the relay 10 also includes a housing 200, and the composite contact is connected to the housing 200 and inserted into the housing 200. The first connecting body 110 of the composite contact faces inward towards the housing 200, contacting or disconnecting with other structures within the housing 200, thereby achieving circuit connection or disconnection. The second connecting body 120 of the composite contact faces outward towards the housing 200 to connect with other structures, such as by welding to the adapter 20. The substrate of the structure within the housing 200 that contacts the first connecting body 110 can be the same as the substrate of the first connecting body 110, and the substrate of the adapter 20 can be the same as the substrate of the second connecting body 120 to reduce contact resistance.

[0104] Please continue reading Figure 5 As shown, the relay 10 also includes a coil 300, a moving contact 400 and a moving armature 500 disposed in the housing 200; the coil 300 is sleeved outside the moving armature 500, and the moving armature 500 is connected to the moving contact 400 in a driving manner. When the coil 300 is energized, it drives the moving armature 500 to drive the moving contact 400 to conduct or disconnect with the composite contact.

[0105] Specifically, the housing 200 may include a first housing 210 and a second housing 220, which are arranged along a first direction X. A composite contact is inserted into the first housing 210, and a moving contact 400 is located inside the first housing 210. A coil 300 and a moving armature 500 are both disposed inside the second housing 220, with the coil 300 sleeved outside the moving armature 500. The composite contact is a stationary contact, and the material of the moving contact 400 can be the same as that of the first connecting body 110 to reduce resistance during conduction. A support plate 230 may be provided between the first housing 210 and the second housing 220. The moving armature 500 includes a spindle 510, which passes through the support plate 230, with part of the spindle 510 located inside the first housing 210 and part inside the second housing 220.

[0106] When the coil 300 is energized, under the action of electromagnetic force, the moving armature 500 drives the spindle 510 to move closer to the moving contact 400, and pushes the moving contact 400 towards the composite contact. The moving contact 400 contacts the first connecting body 110 of the composite contact, and the moving contact 400 and the composite contact are connected, and the relay 10 is in the closed state. At the same time, it is connected to the adapter 20 through the second connecting body 120. When the coil 300 is de-energized, the electromagnetic force on the moving armature 500 disappears, and the spindle 510 and the moving contact 400 move away from the composite contact along the first direction X, and the moving contact 400 is disconnected from the composite contact. At this time, the relay 10 is in the open circuit state, thereby cutting off the connection between the moving contact 400 and the adapter 20.

[0107] Please continue reading Figure 5 As shown, the housing 200 also includes a sleeve 240 and a connecting platform 250. The sleeve 240 is located in the second housing 220, sleeved on the outside of the moving armature 500, and positioned between the moving armature 500 and the coil 300. The connecting platform 250 is connected between the first housing 210 and the support plate 230. The sleeve 240, support plate 230, connecting platform 250, and sidewall of the first housing 210 are connected sequentially. For example, the sleeve 240 can be welded to the side of the support plate 230 facing the second housing 220, one end of the connecting platform 250 can be welded to the side of the support plate 230 facing the first housing 210, and the other end can be welded to the first housing 210. This ensures the sealing of the working space of the moving contact 400 and the composite contact, preventing moisture or contaminants from the external environment from adhering to the contact surface of the moving contact 400 or the composite contact, thus avoiding abnormal conduction. Other structures of the relay 10 can refer to existing relays 10, and will not be described in detail here.

[0108] This application also provides an electrical device, including the electrical connector 100 provided in the above embodiments, or the electrical components provided in the above embodiments.

[0109] The electrical equipment can be vehicles, aircraft, ferries, computers, or energy storage cabinets that use battery packs for power supply. Vehicles can be electric vehicles / electric cars, pure electric vehicles, hybrid electric vehicles, range-extended electric vehicles, plug-in hybrid electric vehicles, or new energy vehicles.

[0110] The electrical equipment includes a battery power distribution unit, a battery pack, and a relay 10, which is connected between the battery pack and the battery power distribution unit. An electrical connector 100 is the stationary contact of the relay 10, used to connect or disconnect with the moving contact of the relay 10, thereby connecting or disconnecting the battery power distribution unit from the battery pack, thus physically switching the high-voltage circuit on and off.

[0111] The electrical connector 100 provided in this application will be further described below through specific embodiments.

[0112] Example 1

[0113] See Figure 8 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 1, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 2.5%.

[0114] Tests showed that the resistance of the electrical connector 100 in Example 1 was 0.01570 mΩ, and the bonding strength between the first connector 110 and the second connector 120 was 5.65 MPa. It should be noted that... Figures 8 to 20 In the image, only a portion of the first connector 110 and a portion of the second connector 120 located on both sides of the reaction layer 130 are shown.

[0115] Example 2

[0116] The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 2, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 3.5%.

[0117] According to the test, the resistance of the electrical connector 100 in Example 2 is 0.0207mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 11.68MPa.

[0118] Example 3

[0119] See Figure 9 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 3, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 5%.

[0120] According to the test, the resistance of the electrical connector 100 in Example 3 is 0.0242mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 16.06MPa.

[0121] Example 4

[0122] See Figure 10 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 4, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 10%.

[0123] According to the test, the resistance of the electrical connector 100 in Example 4 is 0.0303mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 20.11MPa.

[0124] Example 5

[0125] See Figure 11 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 5, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 15%.

[0126] According to the test, the resistance of the electrical connector 100 in Example 5 is 0.0455mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 24.17MPa.

[0127] Example 6

[0128] See Figure 12 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 6, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 20%.

[0129] According to the test, the resistance of the electrical connector 100 in Example 6 is 0.0547mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 26.68MPa.

[0130] Example 7

[0131] See Figure 13 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 7, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 25%.

[0132] According to the test, the resistance of the electrical connector 100 in Example 7 is 0.06089mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 28.23MPa.

[0133] Example 8

[0134] See Figure 14 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 8, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 30%.

[0135] According to the test, the resistance of the electrical connector 100 in Example 8 is 0.0736mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 30.14MPa.

[0136] Example 9

[0137] See Figure 15 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 9, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 40%.

[0138] According to the test, the resistance of the electrical connector 100 in Example 9 is 0.0949mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 33.72MPa.

[0139] Example 10

[0140] See Figure 16 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 10, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 50%.

[0141] According to the test, the resistance of the electrical connector 100 in Example 10 is 0.1105mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 33.59MPa.

[0142] Example 11

[0143] See Figure 17 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 11, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 60%.

[0144] According to the test, the resistance of the electrical connector 100 in Example 11 is 0.1256mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 28.03MPa.

[0145] Example 12

[0146] See Figure 18 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 12, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 70%.

[0147] According to the test, the resistance of the electrical connector 100 in Example 12 is 0.15mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 24.02MPa.

[0148] Example 13

[0149] See Figure 19 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 13, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 75%.

[0150] According to the test, the resistance of the electrical connector 100 in Example 13 is 0.1638mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 20.36MPa.

[0151] Example 14

[0152] See Figure 20 As shown, the cross-section of the electrical connector 100 is obtained using a scanning electron microscope. The first connector 110 and the second connector 120 are diffusion welded to form a reaction layer 130. In Example 14, the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is 80%.

[0153] According to the test, the resistance of the electrical connector 100 in Example 14 is 0.1798mΩ, and the bonding strength of the first connector 110 and the second connector 120 is 14.97MPa.

[0154] Table 1. Specific test results of Examples 1 to 14

[0155]

[0156]

[0157] The test results of Examples 1 to 14 above are shown in Table 1. (See Table 1 and...) Figures 6 to 20As shown, as the ratio P of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 increases, the resistance of the electrical connector 100 gradually increases. The bonding strength of the first connector 110 and the second connector 120 gradually increases as the ratio P increases from 2.5% to 40%, and gradually decreases as the ratio P increases from 40% to 80%. Therefore, the ratio P can be greater than or equal to 15% and less than or equal to 70%, so that the first connector 110 and the second connector 120 in the electrical connector 100 can have high bonding strength and the electrical connector 100 has excellent conductivity.

[0158] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application 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 this application.

Claims

1. An electrical connector, characterized in that, include: First connector (110); The second connector (120) has a different substrate from the first connector (110), and the second connector (120) and the first connector (110) are arranged along a first direction. A reactive layer (130) is formed by the diffusion of the substrate of the first connector (110) and the substrate of the second connector (120) toward each other at the contact interface; The thickness of the reaction layer (130) is a first thickness W1, and the minimum thickness of the first connector (110) and the second connector (120) in the region where the reaction layer (130) is formed is a second thickness W2. The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 10% and less than or equal to 75%.

2. The electrical connector according to claim 1, characterized in that, The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 15% and less than or equal to 70%.

3. The electrical connector according to claim 2, characterized in that, The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 15% and less than or equal to 60%.

4. The electrical connector according to claim 3, characterized in that, The ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 25% and less than or equal to 60%.

5. The electrical connector according to claim 1, characterized in that, One of the first connector (110) and the second connector (120) has at least one protrusion (121) and the other has at least one recess (111), with at least one of the protrusions (121) inserted into at least one of the recesses (111).

6. The electrical connector according to claim 5, characterized in that, The expansion coefficient of the first connector (110) is smaller than that of the second connector (120). The first connector (110) is provided with at least one recess (111), and the second connector (120) is provided with at least one protrusion (121).

7. The electrical connector according to claim 6, characterized in that, The first connector (110) includes a first bottom wall (112) and a first side wall (113), the first side wall (113) surrounding the periphery of the first bottom wall (112) to form the recess (111); The protrusion (121) has a second bottom wall (122) and a second side wall (123); the reaction layer (130) is between the first side wall (113) and the second side wall (123), and the reaction layer (130) is between the first bottom wall (112) and the second bottom wall (122).

8. The electrical connector according to claim 7, characterized in that, The thickness of the first sidewall (113) is the second thickness W2, and the ratio of the first thickness W1 to the sum of the first thickness W1 and the second thickness W2 is greater than or equal to 25% and less than or equal to 60%.

9. The electrical connector according to any one of claims 1 to 8, characterized in that, The conductivity of the reaction layer (130) is less than that of the second connector (120), and the conductivity of the first connector (110) is greater than that of the second connector (120).

10. The electrical connector according to claim 9, characterized in that, The strength of the reaction layer (130) is less than the strength of the second connector (120), and the strength of the first connector (110) is greater than the strength of the second connector (120).

11. The electrical connector according to claim 10, characterized in that, The substrate of the first connector (110) includes copper and its alloys; And / or, the substrate of the second connector (120) includes aluminum and its alloys.

12. An electrical component, characterized in that, Includes the electrical connector as described in any one of claims 1-11.

13. The electrical component according to claim 12, characterized in that, The electrical components are relays (10), transformers, fuses, busbars, radiators, or printed circuit boards.

14. The electrical component according to claim 13, characterized in that, The electrical component is the relay (10), and the electrical connector (100) is the composite contact of the relay (10); The relay (10) also includes a housing (200), and the composite contact is connected to the housing (200) and inserted into the housing (200).

15. The electrical component according to claim 14, characterized in that, The relay (10) also includes a coil (300), a moving contact (400), and a moving armature (500) disposed within the housing (200); The coil (300) is sleeved outside the moving armature (500), and the moving armature (500) is connected to the moving contact (400). When the coil (300) is energized, it drives the moving armature (500) to make the moving contact (400) connect or disconnect from the composite contact.

16. An electrical appliance, characterized in that, It includes the electrical connector (100) as described in any one of claims 1-11, or the electrical element as described in any one of claims 12-15.

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