Enhanced copper-aluminum connection structure and method of manufacturing the same

Abstract

The application discloses an enhanced copper-aluminum connecting structure, which comprises a first component and a second component, the first component and the second component are welded to form a joint surface, a bevel body is formed through material removal processing, and the joint surface is located in the bevel body. The joint surface of the first component and the second component is accurately formed in the internal structure of the bevel body. The innovative design can maximize the retention of the second component material on the bevel body, ensure the full play of the electrical performance and the connecting strength of the material, and significantly improve the mechanical strength of the overall structure through the optimized arrangement of the joint surface. The manufacturing method of the application forms the joint surface in the bevel body through friction welding and turning processing, the manufacturing process is simple, the turning processing amount is reduced under the condition of the same specification of products, the machining cutting time is shortened, the generation of waste is effectively reduced, the production cost is effectively reduced, and large-scale production and application are facilitated.

Description

Technical Field

[0001] This invention relates to the field of electrical connection technology, specifically to an enhanced copper-aluminum connection structure and its manufacturing method, which is particularly suitable for efficient and reliable connection of dissimilar metals such as copper and aluminum in fields such as power transmission, electronic equipment and new energy vehicles. Background Technology

[0002] Copper and aluminum are two widely used metallic materials in electrical connections. Copper has excellent electrical conductivity and mechanical strength, while aluminum has the advantages of being lightweight and low-cost. However, direct copper-aluminum connections present the following technical problems: Electrochemical corrosion: Copper and aluminum are prone to galvanic corrosion in humid environments, leading to increased resistance at the connection point and even failure. Difference in thermal expansion coefficients: Copper and aluminum have different thermal expansion coefficients, which can easily generate stress during temperature changes, causing the connection to loosen or break. Low interface bonding strength: Traditional mechanical connections (such as bolted connections) or welding methods are difficult to achieve high-strength bonding at the copper-aluminum interface, affecting the reliability and durability of the connection. Complex processes and high production costs: Existing technologies using plating, transition layers, or special welding processes can partially solve the problems, but these processes are complex and costly. Summary of the Invention

[0003] The purpose of this invention is to provide an enhanced copper-aluminum connection structure and its manufacturing method. The enhanced copper-aluminum connection structure of this invention has high conductivity, mechanical strength, and corrosion resistance. The manufacturing method of this invention has a simple process and low production cost.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: an enhanced copper-aluminum connection structure, comprising a first component and a second component, wherein the first component and the second component are welded to form a mating surface, and a beveled body is formed by material removal, wherein the mating surface is located within the beveled body. By forming the mating surface within the beveled body, the radial cross-sectional area of ​​the first component at the connection point is increased, the contact resistance at the connection point of the first component and the second component is reduced, and the electrical performance is improved.

[0005] In the aforementioned reinforced copper-aluminum connection structure, the diameter D3 of the mating surface is smaller than the diameter D1 of the first component and larger than the diameter D2 of the second structural component. This ensures that the mating surface is formed within the inclined plane.

[0006] In the aforementioned reinforced copper-aluminum connection structure, the radial cross-sectional area of ​​the mating surface is smaller than the radial cross-sectional area of ​​the first component but larger than the radial cross-sectional area of ​​the second component. This ensures that the mating surface is formed within the inclined plane.

[0007] In the aforementioned reinforced copper-aluminum connection structure, the inclined body comprises an aluminum structure and a copper structure, with one side of the bonding surface being an aluminum structure and the other side being a copper structure. The copper structure on the other side of the bonding surface effectively enhances the bonding strength, preventing failures caused by stress or corrosion, effectively inhibiting electrochemical corrosion, and extending the service life of the connection structure of this invention.

[0008] In the aforementioned reinforced copper-aluminum connection structure, the inclined body includes an outer inclined surface that connects to the outer surfaces of the first component and the second component, respectively. The first component includes a central axis, and the angle θ between the outer inclined surface and the extension line of the central axis or the axis of the outer surface of the first component is 30º~75º. Depending on different product requirements, the angle θ between the outer inclined surface of the inclined body and the extension line of the central axis or the axis of the outer surface of the first component can be set within the range of 30º~75º.

[0009] In the aforementioned reinforced copper-aluminum connection structure, the included angle α between the outer inclined surface and the axis of the outer surface of the second component is 150º~135º. Depending on different product requirements, the included angle α between the outer inclined surface and the axis of the outer surface of the second component can be set within the range of 150º~135º.

[0010] In the aforementioned reinforced copper-aluminum connection structure, the diameter D3 of the mating surface is D2 + 1mm to 3mm, and the mating surface is symmetrically formed about the central axis. The symmetrically formed mating surface about the central axis ensures an effective increase in the bonding strength of the present invention.

[0011] In the aforementioned reinforced copper-aluminum connection structure, the first component and the second component are welded together to form a groove, the bottom surface of the groove coincides with the mating surface, and the copper structure is located in the groove; the groove shown is a circular groove; the inclined body also includes an arc surface, which is disposed on the aluminum structure.

[0012] In the aforementioned enhanced copper-aluminum connection structure, the first component is a circular aluminum part; the second component is a circular copper part.

[0013] The manufacturing method of the above-mentioned reinforced copper-aluminum connection structure includes step S01: friction welding the first component and the second component together to form a connection layer of thickness t at the weld joint of the first component and the second component, and forming a bonding surface in the connection layer. Step S02: fixing the end of the friction-welded first component away from the second component; Step S03: turning the second component away from the first component to form an outer inclined surface of the inclined body, the bonding surface being located in the inclined body, the turning tool stopping at a position where all welding residue can be removed, the part of the connection layer protruding from the first component being welding residue, the cutting edge of the turning tool stopping after passing the intersection point B of the outer surface of the first component and the connection layer, the stopping position of the cutting tip of the turning tool being within the range of td, where d is the distance d between the stopping position of the cutting tip and the A side (9) of the connection layer, and d is greater than 0.5mm.

[0014] Compared to existing technologies, this invention precisely forms the mating surface between the first and second components within the internal structure of the inclined plane. This innovative design maximizes the retention of material from the second component on the inclined plane, ensuring the full utilization of its electrical properties and connection strength. The optimized arrangement of the mating surfaces significantly enhances the overall structural mechanical strength. Compared to existing products of the same specifications, this invention increases the radial cross-sectional area of ​​the transition section of the first component through structural optimization, improving stress distribution and effectively reducing the resistance of the connection points, thereby improving the product's electrical performance. These technological improvements make this invention superior to traditional products in both structural strength and electrical performance, demonstrating significant technological advancement and practical value. The manufacturing method of this invention uses friction welding and turning to form the mating surface within the inclined plane. The manufacturing process is simple; under the same product specifications, it reduces the amount of turning work, shortens machining time, effectively reduces waste, and significantly lowers production costs, facilitating large-scale production applications. Attached Figure Description

[0015] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the enhanced copper-aluminum connection structure of the present invention; Figure 2 This is a schematic diagram of the groove structure of the present invention; Figure 3 This is a schematic diagram of the connecting layer structure of the present invention; Figure 4 This is a schematic diagram showing the state in which the first component and the second component of the present invention are welded together.

[0016] Reference numerals: 1-First component, 101-Central axis, 2-Second component, 3-Matching surface, 4-Sloping body, 401-Aluminum structure, 402-Copper structure, 5-Groove, 6-Arc surface, 7-Bottom surface, 8-Outer slope, 9-Side A.

[0017] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0019] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that includes a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to these processes, methods, products, or apparatuses.

[0020] Embodiment 1 of the present invention: An enhanced copper-aluminum connection structure includes a first component 1 and a second component 2. The first component 1 and the second component 2 are welded to form a mating surface 3, and a beveled body 4 is formed by material removal. The mating surface 3 is located within the beveled body 4. During welding, the first component 1 and the second component 2 form a mating surface inside the welding position. The first component 1 is a circular aluminum part; the second component 2 is a circular copper part. After the first component 1 and the second component 2 are connected, the material integrity of the second component 2 on the beveled body can be preserved to the maximum extent. This technical improvement significantly enhances the structural strength of the formed beveled body 4. Compared with existing products of the same specifications, the present invention effectively increases the cross-sectional area of ​​the transition part of the first component 1 and optimizes the material distribution; secondly, through the improved welding structure and material retention technology, the resistance value of the connection part is significantly reduced, thereby improving the overall electrical performance of the product. These technical improvements make the present invention superior to traditional products in terms of structural strength and electrical performance, demonstrating significant technical progress and practical value. The diameter D3 of the mating surface 3 is smaller than the diameter D1 of the first component 1 and larger than the diameter D2 of the second component 2. The diameter of mating surface 3 is D3 = D2 + 1 mm. Mating surface 3 is symmetrically formed about the central axis 101 and perpendicular to the central axis 101. The inclined body 4 includes an aluminum structure 401 and a copper structure 402. One side of mating surface 3 is the aluminum structure 401, and the other side is the copper structure 402. The copper structure 402 significantly improves the tensile strength (by approximately 25%~30%) and shear resistance (by approximately 20%) of the copper-aluminum connection, effectively suppressing the effect of differences in thermal expansion coefficients (copper: 16.5 × 10⁻⁻⁻⁶). 6 / °C, Aluminum: 23.1×10⁻ 6 This invention addresses the stress concentration phenomenon caused by (°C), thus solving the technical problem of easy loosening and breakage at the copper-aluminum connection. The inclined body 4 includes an outer inclined surface 8 that connects to the outer surfaces of the first component 1 and the second component 2 respectively. The first component 1 includes a central axis 101. The angle θ between the outer inclined surface 8 and the extension line of the central axis 101 or the axis of the outer surface of the first component 1 is 30°~75°. Experimental verification and finite element analysis show that when the angle θ is 30°~75°, the tensile strength of the reinforced copper-aluminum connection structure of this invention can be increased to 120%~135% of the design load, and the fatigue life is significantly higher than other angle configurations (p<0.05), meeting the requirements of long-term dynamic load conditions. A groove 5 is formed by welding the first component 1 and the second component 2. The bottom surface 7 of the groove 5 coincides with the mating surface 3, and the copper structure 402 is located in the groove 5. The groove 5 is a circular groove. The inclined body 4 also includes an arc surface 6, which is disposed on the aluminum structure 401.

[0021] Embodiment 2 of the present invention: An enhanced copper-aluminum connection structure includes a first component 1 and a second component 2. The first component 1 and the second component 2 are welded to form a mating surface 3, and a beveled body 4 is formed by material removal. The mating surface 3 is located in the beveled body 4. The mating surface is formed inside the weld position during the welding of the first component 1 and the second component 2. The diameter D3 of the mating surface 3 is smaller than the diameter D1 of the first component 1 and larger than the diameter D2 of the second component 2. The beveled body 4 includes an aluminum structure 401 and a copper structure 402. One side of the mating surface 3 is the aluminum structure 401, and the other side is the copper structure 402. The angle α between the outer beveled surface 8 and the axis of the outer surface of the second component 2 is 150º~135º. The diameter D3 of the mating surface 3 is D2+2mm, and the mating surface 3 is symmetrically formed about the central axis 101. Wherein D2 = 5mm~100mm, specifically D2 = φ19, φ21, or φ29mm, corresponding to D1 = φ25, φ32, or φ40. Finite element simulation and fatigue testing have verified that the diameter of the mating surface 3, D3 = D2 + 2 mm, allows the tensile strength of the reinforced copper-aluminum connection structure of this invention to exceed 150 MPa and the shear strength to reach 90 MPa, while ensuring that the overall weight of the workpiece does not increase by more than 5%, fully meeting the static load and dynamic cyclic load (10) requirements of ISO 6892-1 standard. 6 The first component 1 and the second component 2 are welded together to form a groove 5. The bottom surface 7 of the groove 5 coincides with the mating surface 3. The copper structure 402 is located in the groove 5. The groove 5 is a circular groove. The inclined body 4 also includes an arc surface 6, which is set on the aluminum structure 401. The first component 1 is a circular aluminum part; the second component 2 is a circular copper part.

[0022] Embodiment 3 of the present invention: An enhanced copper-aluminum connection structure includes a first component 1 and a second component 2. The first component 1 and the second component 2 are welded to form a mating surface 3, and a beveled body 4 is formed by material removal. The mating surface 3 is located within the beveled body 4. The mating surface is formed inside the welded area when the first component 1 and the second component 2 are welded. The radial cross-sectional area of ​​the mating surface 3 is smaller than the radial cross-sectional area of ​​the first component 1 and larger than the radial cross-sectional area of ​​the second component 2. The beveled body 4 includes an aluminum structure 401 and a copper structure 402. One side of the mating surface 3 is the aluminum structure 401, and the other side is the copper structure 402. The beveled body 4 includes an outer bevel 8 that connects to the outer surfaces of the first component 1 and the second component 2 respectively. The first component 1 includes a central axis 101, and the angle α between the outer bevel 8 and the axis of the outer surface of the second component 2 is 145º. The diameter D3 of the mating surface 3 is D2 + 2.5 mm, and the mating surface 3 is symmetrically formed about the central axis 101. The first component 1 and the second component 2 are welded together to form a groove 5. The bottom surface 7 of the groove 5 coincides with the mating surface 3, and the copper structure 402 is located in the groove 5. The groove 5 is a circular groove. The inclined body 4 also includes an arc surface 6, which is set on the aluminum structure 401. The first component 1 is a circular aluminum part; the second component 2 is a circular copper part. The design of the arc surface 6 optimizes the material distribution, thereby reducing the overall weight of the structure by about 5% to 10%.

[0023] Embodiment 4 of the present invention: An enhanced copper-aluminum connection structure includes a first component 1 and a second component 2. The first component 1 and the second component 2 are welded to form a mating surface 3, and a beveled body 4 is formed by material removal. The mating surface 3 is located within the beveled body 4. The mating surface is formed inside the welded area when the first component 1 and the second component 2 are welded. The radial cross-sectional area of ​​the mating surface 3 is smaller than the radial cross-sectional area of ​​the first component 1 and larger than the radial cross-sectional area of ​​the second component 2. The beveled body 4 includes an aluminum structure 401 and a copper structure 402. One side of the mating surface 3 is the aluminum structure 401, and the other side is the copper structure 402. The beveled body 4 includes an outer bevel 8 that connects to the outer surfaces of the first component 1 and the second component 2, respectively. The first component 1 includes a central axis 101. The angle θ between the outer bevel 8 and the extension line of the central axis 101 or the axis of the outer surface of the first component 1 is 45º. The diameter D3 of the mating surface 3 is D2 + 3 mm, and the mating surface 3 is symmetrically formed about the central axis 101. The first component 1 and the second component 2 are welded together to form a groove 5. The bottom surface 7 of the groove 5 coincides with the mating surface 3. The copper structure 402 is located in the groove 5. The groove 5 is a circular groove. The inclined body 4 also includes an arc surface 6, which is set on the aluminum structure 401. The first component 1 is a circular aluminum part; the second component 2 is a circular copper part.

[0024] Embodiment 5 of the present invention: A method for manufacturing an enhanced copper-aluminum connection structure, comprising step S01: friction welding a first component and a second component together to form a connection layer of thickness t at the weld joint between the first component and the second component, such as... Figure 3 As shown, a bonding surface is formed in the connecting layer. Step S02: Fix the end of the first component, which is friction-welded together, away from the second component; Step S03: Perform turning machining from the end of the second component away from the first component to machine the outer inclined surface of the inclined body. The bonding surface is located in the inclined body. The turning tool stops at a position where all welding residue can be removed. The part of the connecting layer protruding from the first component is welding residue. The cutting edge of the turning tool stops after passing the intersection point B of the outer surface of the first component and the connecting layer. The stopping position of the cutting tip of the turning tool is within the range of td, where d is the distance d between the stopping position of the cutting tip and the A side 9 of the connecting layer, and d is greater than 0.5mm.

[0025] The manufacturing method of this invention is simple, reducing machining operations by approximately 20-50% compared to traditional turning methods, shortening the production cycle by more than 20%, increasing material utilization to 95%, and reducing waste generation to below 5%. Furthermore, through process optimization, the unit production cost is reduced by approximately 30%, making it suitable for large-scale industrial production.

[0026] The working principle of this invention is as follows: The first component 1 is made of aluminum, and the second component 2 is made of copper. The first component 1 and the second component are first integrated by friction welding, forming a mating surface 3 at the connection point of the first component 1 and the second component 2 during friction welding. Then, the residual material formed at the connection point during friction welding is removed by turning, and the outer bevel 8 of the inclined body 4 is formed by turning. This makes the mating surface 3 located in the inclined body 4. One side of the mating surface 3 is made of aluminum, which can increase the radial cross-sectional area of ​​the transition part of the first component 1 and effectively reduce the resistance. The other side of the mating surface 3 is made of copper, so that the copper part of the second component 2 is located in the inclined body 4, thereby effectively strengthening the structural strength of the connection part.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of this application. It will be apparent to those skilled in the art that this application is not limited to the details of the exemplary embodiments described above, and that this application can be implemented in other specific forms without departing from the spirit or basic characteristics of this application. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this application is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this application. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0028] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An enhanced copper-aluminum connection structure, characterized in that, It includes a first component (1) and a second component (2), the first component (1) and the second component (2) are welded to form a joint surface (3), and a slope body (4) is formed by material removal processing, wherein the joint surface (3) is located in the slope body (4).

2. The enhanced copper-aluminum connection structure according to claim 1, characterized in that, The diameter D3 of the mating surface (3) is smaller than the diameter D1 of the first component (1) and larger than the diameter D2 of the second component (2).

3. The enhanced copper-aluminum connection structure according to claim 1, characterized in that, The radial cross-sectional area of ​​the mating surface (3) is smaller than the radial cross-sectional area of ​​the first component (1) and larger than the radial cross-sectional area of ​​the second component (2).

4. The enhanced copper-aluminum connection structure according to claim 2 or 3, characterized in that, The inclined body (4) includes an aluminum structure (401) and a copper structure (402). One side of the joint surface (3) is the aluminum structure (401), and the other side of the joint surface (3) is the copper structure (402).

5. The enhanced copper-aluminum connection structure according to claim 4, characterized in that, The inclined body (4) includes an outer inclined surface (8) that is connected to the outer surface of the first component (1) and the outer surface of the second component (2), respectively. The first component (1) includes a central axis (101). The angle θ between the outer inclined surface (8) and the extension line of the central axis (101) or the axis of the outer surface of the first component (1) is 30º~75º.

6. The enhanced copper-aluminum connection structure according to claim 5, characterized in that, The included angle α between the outer inclined surface (8) and the axis of the outer surface of the second component (2) is 150º~135º.

7. The enhanced copper-aluminum connection structure according to claim 6, characterized in that, The diameter of the mating surface (3) is D3 = D2 + 1 mm ~ 3 mm, and the mating surface (3) is formed symmetrically about the central axis (101).

8. The enhanced copper-aluminum connection structure according to claim 7, characterized in that, The first component (1) and the second component (2) are welded together to form a groove (5). The bottom surface (7) of the groove (5) coincides with the mating surface (3). The copper structure (402) is located in the groove (5). The groove (5) is a circular groove. The inclined body (4) also includes an arc surface (6). The arc surface (6) is disposed on the aluminum structure (401).

9. The enhanced copper-aluminum connection structure according to claim 8, characterized in that, The first component (1) is a circular aluminum part; the second component (2) is a circular copper part.

10. A method for manufacturing the enhanced copper-aluminum connection structure according to any one of claims 1 to 9, characterized in that, include Step S01: Friction weld the first component and the second component together to form a connecting layer of thickness t at the weld joint between the first component and the second component, and form a bonding surface in the connecting layer; Step S02: Fix the end of the first component, which is friction-welded together, away from the second component; Step S03: Perform turning machining on the end of the second component away from the first component to create the outer bevel of the inclined plane. The mating surface is located within the inclined plane. The turning tool stops at a position where all welding residue can be removed. The portion of the connecting layer protruding from the first component is welding residue. The cutting edge of the turning tool stops after passing the intersection point B between the outer surface of the first component and the connecting layer. The tool tip of the turning tool stops within the range of td, where d is the distance d between the tool tip stopping position and the A side (9) of the connecting layer, and d is greater than 0.5mm.

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