Copper terminal suitable for ultrasonic welding of aluminum conductor

Abstract

The utility model discloses a copper terminal suitable for aluminum conductor ultrasonic welding, which comprises a copper terminal body and an aluminum conductor core of an aluminum conductor, the copper terminal body comprises a bolt fixing part and a welding part, the bolt fixing part and the welding part are connected through an inclined part, and one end of the bolt fixing part far away from the inclined part is provided with an anti-rotation piece. The end, away from the inclined part, of the welding part is provided with a fixing piece for fixing an aluminum wire. According to the utility model, the welding between the copper and the aluminum can be realized, the electrical property and the mechanical property are better, the contact resistivity is better, the lead wrapping structure of the copper terminal is reduced, the copper consumption is reduced by 5%, the aluminum lead is used for replacing the copper lead, and under the same load, the weight can be reduced by 20%, and the cost can be reduced by 20%.

Description

Technical Field

[0001] The utility model relates to the technical field of wire harness manufacturing, in particular to a copper terminal suitable for ultrasonic welding of aluminum conductors. Background Art

[0002] The current trend of lightweighting in the passenger car market can effectively reduce, optimize or improve the endurance of electric vehicles. The application of aluminum wires can effectively reduce the weight of power cables by more than 20%. In the existing common connection technology of wiring harnesses, the connection method of terminals and wires is mainly based on crimping, that is, the conductor core of the wire is placed in the connector of the terminal, and the terminal crimping mold is used to crimp the terminal and the wire together using a mechanical cold pressing process. This process is only suitable for the connection of copper wires. Aluminum wires are not suitable for cold pressing process connection due to their special ductility. Chinese invention patent CN1073478C discloses a method for electromagnetically connecting or welding at least two metal parts, but the solution still has the following unsolvable technical problems and technical defects: the technology is to weld two metals of undefined categories together, and the welding method described in the patent cannot solve the welding of copper and aluminum, or the particularity of welding copper terminals and aluminum wires in the field of wiring harnesses. The direct contact between the copper terminal and the aluminum wire will cause electrochemical corrosion in the wiring harness use environment. Over time, the resistance of the copper terminal and the aluminum wire joint will increase, the voltage drop will increase, and the pull-out force and tearing force will decrease, so the technology cannot be directly applied to the preparation of copper terminal and aluminum wire joints. Utility Model Content

[0003] Based on this, the purpose of the utility model is to provide a copper terminal suitable for ultrasonic welding of aluminum conductors to solve the technical problems mentioned in the above background.

[0004] To achieve the above-mentioned purpose, the utility model provides the following technical solution: a copper terminal suitable for ultrasonic welding of aluminum wires, comprising a copper terminal body and an aluminum conductor core of the aluminum wire, the copper terminal body comprising a bolt fixing portion and a welding portion, the bolt fixing portion and the welding portion are connected by an inclined portion, an anti-rotation part is provided at one end of the bolt fixing portion away from the inclined portion, and a fixing part for fixing the aluminum wire is provided at one end of the welding portion away from the inclined portion.

[0005] Furthermore, the surface length and width of the welding portion are both 15 mm, and a plurality of through holes are provided.

[0006] Furthermore, the fixing member for fixing the aluminum wire includes a mounting portion with a semicircular bottom and clamping members arranged on both sides of the mounting portion.

[0007] Preferably, the clamping member is made of a flexible metal material.

[0008] Furthermore, a bolt fixing hole is provided above the bolt fixing portion.

[0009] In summary, the utility model can realize welding between copper and aluminum and make the electrical and mechanical properties better, with better contact resistivity, and the copper terminal reduces the wire wrapping structure, the copper usage is reduced by 5%, and the use of aluminum wire instead of copper wire can reduce the weight by 20% and the cost by 20% under the same load. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 This is a schematic diagram of the three-dimensional structure of the copper terminal body of the utility model;

[0011] Figure 2 This is a schematic diagram of the main structure of the copper terminal body of the utility model;

[0012] Figure 3 This is a schematic diagram of the copper terminal body and the aluminum wire after welding. DETAILED DESCRIPTION

[0013] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. The embodiments described below with reference to the drawings are exemplary and are only used to explain the utility model, and cannot be understood as limiting the utility model.

[0014] The following describes an embodiment of the utility model based on its overall structure.

[0015] like Figure 1-Figure 3 As shown, the utility model includes a copper terminal body and an aluminum conductor core 71 of an aluminum conductor 7, the copper terminal body includes a bolt fixing portion 1 and a welding portion 2, the bolt fixing portion 1 and the welding portion 2 are connected by an inclined portion 3, and the inclined portion 3 is connected to make the bolt fixing portion 1 and the welding portion 2 have a 4mm drop, which is used to prevent the welding area from interfering with peripheral equipment, the surface length and width of the welding portion 2 are both 15mm, and 80 0.5*0.5mm through holes are provided, which are used to increase the contact area between the copper terminal body and the aluminum conductor core 71, thereby improving the release force after welding. A bolt fixing hole 11 is provided above the bolt fixing part 1, an anti-rotation part 4 is provided at one end of the bolt fixing part 1 away from the inclined part 3, a fixing part 5 for fixing the aluminum wire 7 is provided at one end of the welding part 2 away from the inclined part 3, the fixing part 5 includes a mounting part 51 with a semicircular bottom and clamping parts 52 arranged on both sides of the mounting part 51, a 2mm drop is provided between the bottom of the mounting part 51 and the welding part 2, mainly used to fix the wire skin of the aluminum wire 7, disperse the stress in the welding area, and achieve the purpose of protecting the welding point, the clamping part 52 is made of flexible metal material, preferably brass, and the surface is tinned by 2um.

[0016] When the copper terminal of the utility model is welded with the aluminum conductor, the end of the aluminum conductor 7 is fixed to the mounting portion 51 so that the aluminum conductor core 71 is placed above the welding portion 2, and then the clamping member 52 is folded in half to firmly fix the aluminum conductor 7 on the fixing member 5, and finally the aluminum conductor core 71 is welded with the welding portion 2 by ultrasonic wave. The utility model can realize the welding between copper and aluminum and make the electrical and mechanical properties better, and has better contact resistivity. The copper terminal reduces the wire wrapping structure, and the copper usage is reduced by 5%. Using aluminum conductors instead of copper conductors can reduce the weight by 20% and the cost by 20% under the same load.

[0017] Although an embodiment of the utility model has been shown and described, this specific embodiment is merely an explanation of the utility model and is not a limitation of the utility model. The specific features, structures, materials or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. After reading this specification, those skilled in the art may make modifications, substitutions and variations to the embodiments without creative contributions as needed without departing from the principles and purpose of the utility model. However, as long as they are within the scope of the claims of the utility model, they are protected by patent law.

Claims

1. A copper terminal suitable for ultrasonic welding of aluminum conductors, comprising a copper terminal body and an aluminum conductor core of an aluminum conductor, characterized in that: The copper terminal body includes a bolt fixing part and a welding part, the bolt fixing part and the welding part are connected by an inclined part, an anti-rotation part is provided at one end of the bolt fixing part away from the inclined part, and a fixing part for fixing the aluminum wire is provided at one end of the welding part away from the inclined part.

2. A copper terminal suitable for ultrasonic welding of aluminum conductors according to claim 1, characterized in that: The surface length and width of the welding part are both 15 mm, and a plurality of through holes are provided.

3. A copper terminal suitable for ultrasonic welding of aluminum conductors according to claim 1, characterized in that: The fixing piece for fixing the aluminum conductor comprises a mounting portion with a semicircular bottom and clamping pieces arranged on both sides of the mounting portion.

4. A copper terminal suitable for ultrasonic welding of aluminum conductors according to claim 3, characterized in that: The clamping piece is made of flexible metal material.

5. The copper terminal suitable for ultrasonic welding of aluminum conductors according to claim 1, characterized in that: A bolt fixing hole is provided above the bolt fixing portion.

Images