Aluminum busbar using cold-sprayed copper layer for conductive connection

Abstract

An aluminum busbar using a cold spraying copper layer for conductive connection comprises a busbar body, and the busbar body is provided with a connecting structure used for being electrically connected with the outside. The connecting structure comprises an aluminum substrate, the upper end face of the aluminum substrate is provided with a first cold spraying copper layer structure, the first cold spraying copper layer structure is used for replacing an electroplated layer to be connected with a copper conductive part, and electrochemical corrosion of the aluminum substrate and the copper conductive part is avoided. The cold spraying copper layer structure is composed of copper powder sprayed on the aluminum busbar by a supersonic spray gun. The supersonic spray gun has the advantages that the precision of spraying by adopting the supersonic spray gun is extremely high, other positions do not need to be shielded, the processing cost is low, and the efficiency is high. In the process of adding the cold spraying copper layer, raw materials such as electroplating liquid which easily pollute the environment do not need to be used, and the environmental protection property of production and manufacturing is improved. In the spraying process of the cold spraying copper layer, due to the fact that the spraying temperature is low and phase change and oxidation phenomena do not exist, the formed coating is more compact, and the problem that the performance of the busbar can be changed due to high-temperature treatment is avoided.

Description

Technical Field

[0001] The utility model relates to the technical field of busbar electrical connection, in particular to an aluminum busbar that uses a cold-sprayed copper layer for conductive connection. Background Art

[0002] Aluminum busbar is a conductive bus made of aluminum material. It is usually 50% lighter than copper busbar, which can save total weight in battery pack design while maintaining reliable electrical performance. In addition, aluminum busbar has a high level of conductivity, low resistivity and good bendability, which makes it perform well in power distribution system, so it is widely used in the power system of new energy vehicles.

[0003] In the power system of new energy vehicles, aluminum busbars and copper conductive components often exist at the same time. During use, the aluminum busbar often needs to be directly connected to the copper conductive components. In order to prevent electrochemical corrosion between copper and aluminum, it is generally necessary to perform local copper electroplating on the connection ends of the aluminum busbar.

[0004] However, the traditional electroplating process requires the product to be immersed in the electroplating tank, so the cost of local electroplating of large-sized aluminum busbars is quite high. Either the product is completely electroplated, which will change the mechanical properties of the aluminum busbar; or the parts of the product that do not need to be electroplated are masked, but the masking cost is extremely high, which greatly limits the application of electroplating; and because the process of artificially removing the masking layer is complicated and costly, it cannot meet the design requirements of local surface treatment of large-sized aluminum busbar connection ends. At the same time, the electroplating process is not environmentally friendly, which is contrary to the original intention of new energy to protect the environment.

[0005] Therefore, in view of the deficiencies in the prior art, the utility model designs an aluminum busbar that uses a cold-sprayed copper layer for conductive connection to solve the above problems.

[0006] It should be noted that the above introduction to the technical background is only for the convenience of providing a clear and complete description of the technical solution of the utility model and facilitating the understanding of those skilled in the art. It cannot be considered that the above contents are well known to those skilled in the art simply because they are explained in the background technology of the utility model. Utility Model Content

[0007] In order to overcome the above-mentioned deficiencies in the prior art, the utility model aims to provide an aluminum busbar using a cold-sprayed copper layer for conductive connection.

[0008] In order to achieve the above-mentioned purpose and other related purposes, the technical solution provided by the utility model is: an aluminum busbar using a cold-sprayed copper layer for conductive connection, comprising a busbar body, on which a connection structure is provided for electrical connection with the outside; the connection structure comprises an aluminum substrate, on the upper end surface of which a first cold-sprayed copper layer structure is provided for connecting with a copper conductive component instead of an electroplating layer, thereby avoiding electrochemical corrosion between the aluminum substrate and the copper conductive component.

[0009] The preferred technical solution is: a second cold-sprayed copper layer structure is provided on the lower end surface of the aluminum substrate, and cold-sprayed copper layers are provided on both sides of the aluminum substrate. Any side can be selected for connection with the copper conductive component, reducing the difficulty of connecting with the copper conductive component.

[0010] The preferred technical solution is: the first cold-sprayed copper layer structure and the second cold-sprayed copper layer structure are both composed of copper powder sprayed on the aluminum busbar by a supersonic spray gun. Using a supersonic spray gun to spray copper powder on the surface of a specified area of ​​the aluminum busbar instead of local electroplating can accurately spray the local area.

[0011] The preferred technical solution is: a connection positioning hole is also provided on the connection structure for electrical connection and mechanical fixation.

[0012] The preferred technical solution is: the covering area of ​​the first cold-sprayed copper layer structure is inside the upper end surface area of ​​the connecting structure; the covering area of ​​the second cold-sprayed copper layer structure is inside the lower end surface area of ​​the connecting structure.

[0013] The preferred technical solution is that the upper end surface and the lower end surface of the aluminum substrate can be inclined structures.

[0014] The structural features of the above scheme are explained as follows: In order to solve the high cost and environmental pollution caused by the electroplating process of the traditional aluminum busbar for the connection surface treatment, the utility model adopts a supersonic spray gun to spray copper powder on the surface of the specified area of ​​the aluminum busbar to replace the local electroplating, and uses a cold spray copper layer instead of an electroplated copper layer to protect the connection end surface, which has the following advantages:

[0015] 1) The supersonic spray gun has extremely high spraying precision, and there is no need to mask other positions. The processing cost is low and the efficiency is high.

[0016] 2) In the process of adding the cold spray copper layer, there is no need to use raw materials such as electroplating liquid that are easy to pollute the environment, which improves the environmental friendliness of production.

[0017] 3) During the cold spraying copper layer spraying process, due to its low spraying temperature, there is no phase change and oxidation phenomenon, so the formed coating is more dense, avoiding the problem that high temperature treatment may change the performance of the busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1This is a schematic diagram of the structure of an aluminum busbar that uses a cold-sprayed copper layer for conductive connection according to the utility model;

[0019] Figure 2 for Figure 1 A partial enlarged view of point A in the middle.

[0020] In the above drawings, 1, busbar body; 2, connection structure; 21, aluminum substrate; 22, first cold-sprayed copper layer structure; 23, second cold-sprayed copper layer structure; 24, connection positioning hole. DETAILED DESCRIPTION

[0021] The following is a description of the implementation of the present invention by means of specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0022] In the description of the present utility model, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the utility model product is usually placed when in use. They are only for the convenience of describing the present utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present utility model. In addition, terms such as "horizontal", "vertical", and "overhanging" do not mean that the components are required to be absolutely horizontal or overhanging, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0023] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection, it can be a mechanical connection, it can be an electrical connection, it can be a direct connection, it can be indirectly connected through an intermediate medium, and it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] Example:

[0025] like Figure 1 and Figure 2As shown, the utility model discloses an aluminum busbar that uses a cold-sprayed copper layer for conductive connection, including a busbar body 1, on which a connection structure 2 is provided; the connection structure 2 includes an aluminum substrate 21, the upper end surface of the aluminum substrate 21 is provided with a first cold-sprayed copper layer structure 22, and the lower end surface of the aluminum substrate 21 is provided with a second cold-sprayed copper layer structure 23, which is used to connect with an external copper conductive part to ensure the stability of the connection end surface and avoid electrochemical corrosion between the aluminum substrate 21 and the external copper conductive part. It should be noted that the above structure is merely exemplary and not restrictive. In this embodiment, the upper end surface and the lower end surface of the connection structure 2 are respectively provided with a first cold-sprayed copper layer structure 22 and a second cold-sprayed copper layer structure 23, but in other embodiments, the connection structure 2 can only be provided with a cold-sprayed copper layer structure on the upper end surface or the lower end surface. It should also be noted that in this embodiment, there is only one connection structure 2, but in other embodiments, there can be multiple connection structures 2 and they can be set at any position.

[0026] like Figure 1 and Figure 2 As shown, the connection structure 2 is also provided with a connection positioning hole 24, which is used for positioning or clamping when connecting with an external copper conductive part; the coverage area of ​​the first cold-sprayed copper layer structure 22 is inside the upper end surface area of ​​the connection structure 2; the coverage area of ​​the second cold-sprayed copper layer structure 23 is inside the lower end surface area of ​​the connection structure 2, so as to avoid the first cold-sprayed copper layer structure 22 and the second cold-sprayed copper layer structure 23 from affecting the mechanical properties of the busbar body 1; the upper end surface and the lower end surface of the aluminum substrate 21 are planar structures. It should be noted that in this embodiment, the upper end surface and the lower end surface of the aluminum substrate 21 are planar structures, but in other embodiments, the upper end surface and the lower end surface of the aluminum substrate 21 can be inclined structures, which are used for surface treatment of connection surfaces of various shapes to improve the scope of application.

[0027] refer to Figure 1 and Figure 2 As shown, the principle and implementation method of the utility model are as follows: first, determine the area that needs surface treatment at the connection structure 2; then use copper powder to spray accurately on the area that needs surface treatment at room temperature or low temperature with a supersonic spray gun. Due to the low spraying temperature, there is no phase change and oxidation phenomenon. At the same time, the spraying accuracy is high and no masking is required, which reduces the cost and time required for masking and removing the masking. At the same time, copper powder, as a metal material, has a simple processing method and is difficult to pollute the environment, which solves the problem that electroplating is easy to cause damage to the environment.

[0028] To sum up, the utility model discloses an aluminum busbar that uses a cold-sprayed copper layer for conductive connection, which creatively uses cold spraying technology instead of electroplating metal to perform surface treatment on the connection end, thereby reducing the cost and time of surface treatment, while avoiding pollution to the environment, and is more in line with the core purpose of new energy for environmental protection.

[0029] The above embodiments provided by the present invention are only intended to illustrate the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the technology may modify or change the above embodiments without violating the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by a person with ordinary knowledge in the relevant technical field without departing from the spirit and technical ideas disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. An aluminum busbar using a cold-sprayed copper layer for conductive connection, comprising a busbar body (1), wherein a connection structure (2) is provided on the busbar body (1), characterized in that: The connection structure (2) comprises an aluminum substrate (21), and a first cold-sprayed copper layer structure (22) is provided on the upper end surface of the aluminum substrate (21).

2. The aluminum busbar using cold sprayed copper layer for conductive connection according to claim 1, characterized in that: The lower end surface of the aluminum substrate (21) is provided with a second cold-sprayed copper layer structure (23).

3. The aluminum busbar using cold sprayed copper layer for conductive connection according to claim 2, characterized in that: The first cold-sprayed copper layer structure (22) and the second cold-sprayed copper layer structure (23) are both composed of copper powder sprayed on the aluminum busbar by a supersonic spray gun.

4. The aluminum busbar using cold sprayed copper layer for conductive connection according to claim 1, characterized in that: The connection structure (2) is also provided with a connection positioning hole (24).

5. The aluminum busbar using cold sprayed copper layer for conductive connection according to claim 2, characterized in that: The coverage area of ​​the first cold-sprayed copper layer structure (22) is inside the upper end surface area of ​​the connecting structure (2); The coverage area of ​​the second cold-sprayed copper layer structure (23) is inside the lower end surface area of ​​the connecting structure (2).

6. The aluminum busbar using cold sprayed copper layer for conductive connection according to claim 1, characterized in that: The upper end surface and the lower end surface of the aluminum substrate (21) may be inclined structures.

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