Aluminum bar for vehicle current transmission

Abstract

The utility model discloses an aluminum bar for vehicle current transmission, and solves the technical problems of torque attenuation and electrochemical corrosion of the existing copper-to-aluminum connection structure. The aluminum bar comprises an aluminum bar body with a through hole, the through hole is connected with a conducting ring through friction welding, and the reducibility of the conducting ring is larger than that of aluminum. The conductive rings are inserted into the aluminum bar body, so that the hardness of the connecting part of the aluminum bar body and the terminals is enhanced, the aluminum bar body is prevented from being deformed due to long-term extrusion, and the torque attenuation of the connecting structure of the aluminum bar body and the terminals is further avoided; after the aluminum bar body and the conducting ring are connected through friction welding, molecular exchange occurs at the joint of the aluminum bar body and the conducting ring to form alloy, electrochemical corrosion caused by potential difference formed by direct connection of copper and aluminum is avoided, the connection performance of the copper terminal and the aluminum bar is greatly improved, the structural design is simple, the production cost is low, and batch production can be achieved; and high practicability and high economic popularization value are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of automotive wire harnesses, in particular to an aluminum busbar for vehicle current transmission. Background Art

[0002] With the rapid development of new energy vehicles in China, the requirements for vehicle lightweight are getting higher and higher. Coupled with the increasingly fierce competition among major vehicle manufacturers for cost savings, the automotive wire harness industry is bound to develop towards low cost and lightweight. In order to achieve the lightweight of automotive wire harnesses, the prior art has adopted the method of replacing copper busbars with aluminum busbars. This method can not only reduce the weight of the wire harness by 30%, but also reduce the production cost by 20%.

[0003] However, due to the large electrode potential difference between copper and aluminum, when a copper terminal is directly connected to an aluminum busbar, electrochemical corrosion will occur between copper and aluminum under the action of air and water. The aluminum busbar is easily corroded, resulting in an increase in the contact resistance of the copper-aluminum connection area, thereby affecting the electrical conductivity. Moreover, due to the relatively soft texture of the aluminum busbar, when the aluminum busbar is connected to the terminal through bolts and nuts, due to the different thermal expansion coefficients of copper and aluminum, after multiple and long-term high-temperature cycles, the aluminum busbar is easily deformed by extrusion, and the pressure of the nut becomes smaller, resulting in torque attenuation in the connection between the aluminum busbar and the terminal, and further resulting in problems such as gaps and stress relaxation.

[0004] Therefore, there is an urgent need for a copper-to-aluminum connection structure suitable for automotive wire harnesses to improve the connection performance between copper terminals and aluminum busbars. Summary of the Utility Model

[0005] In view of the above deficiencies in the background art, the utility model provides an aluminum busbar for vehicle current transmission, which solves the technical problems of torque attenuation and electrochemical corrosion existing in the existing copper-to-aluminum connection structure.

[0006] The technical solution of this application is as follows:

[0007] An aluminum busbar for vehicle current transmission includes an aluminum busbar body with through holes. The through holes are connected to conductive rings by friction welding, and the reducibility of the conductive ring material is greater than that of aluminum.

[0008] Inserting a conductive ring on the aluminum busbar body strengthens the hardness of the connection between the aluminum busbar body and the terminal, avoiding deformation of the aluminum busbar body due to long-term extrusion, and further avoiding torque attenuation in the connection structure between the aluminum busbar body and the terminal. After the aluminum busbar body and the conductive ring are connected by friction welding, molecular exchange occurs at the joint of the aluminum busbar body and the conductive ring to form an alloy, avoiding electrochemical corrosion caused by the direct connection of copper and aluminum to form a potential difference.

[0009] Preferably, a plurality of through holes are provided. The aluminum busbar body is connected with a plurality of conductive rings through the through holes.

[0010] Preferably, the through hole is a stepped hole, and the conductive ring is a stepped ring matching the stepped hole. The stepped hole can increase the joint surface between the aluminum bar body and the conductive ring, increase the contact area of friction welding, and improve the connection reliability.

[0011] Preferably, the conductive ring is provided with a central hole, and the central hole includes a circular hole and a polygonal hole connected to each other. The central hole is used to connect the terminal. The circular hole can facilitate bolt connection, and the polygonal hole can facilitate fixture fixation of the conductive ring, which is convenient for friction welding.

[0012] Preferably, the circular hole is arranged on the small-diameter section of the stepped ring, and the polygonal hole is arranged on the large-diameter section of the stepped ring. During friction welding, the small-diameter section of the stepped ring is in the front, the large-diameter section is in the back, the circular hole of the central hole is in the front, and the polygonal hole is in the back.

[0013] Preferably, the polygonal hole is a regular polygonal hole, and the aperture of the regular polygonal hole is larger than the aperture of the circular hole. The regular polygonal hole is more convenient for fixture fixation, and the aperture of the regular polygonal hole is larger than the aperture of the circular hole, which is convenient for the bolt to pass through the conductive ring for fixation.

[0014] Preferably, the aluminum bar body is connected with an insulating sheath, and the insulating sheath is arranged at an interval from the through hole. The insulating sheath is used for insulation to improve safety.

[0015] Preferably, the material of the conductive ring is any one or more of copper, steel, zinc, and silver.

[0016] Preferably, the height of the conductive ring is greater than the thickness of the aluminum bar body. After connection by friction welding, the conductive ring extends out of the aluminum bar body, which is convenient for connecting the conductive ring with the terminal.

[0017] Preferably, both end faces of the conductive ring protrude from the surface of the aluminum bar body. It is convenient for connecting the conductive ring with the terminal.

[0018] Compared with the prior art, the technical solution disclosed by the present utility model has the following beneficial effects:

[0019] The present utility model sets a stepped hole on the aluminum bar body, and friction-welds a stepped-ring-shaped conductive ring in the stepped hole. Through the stepped joint surface and the connection method of friction welding, reliable connection between the copper terminal and the aluminum bar is achieved, the application of the aluminum bar is realized, it is applicable to the copper-to-aluminum connection structure of automotive wire harnesses, and the connection performance between the copper terminal and the aluminum bar is improved; the problems of torque attenuation and electrochemical corrosion in the copper-to-aluminum connection structure in the prior art are solved, and the structure design is simple, the production cost is low, and it can be mass-produced; in practical applications, a large number of existing copper bars can be replaced, the weight of the automotive wire harness can be greatly reduced, the cost of the wire harness can be reduced, and it has strong practicability and high economic popularization value. Description of the Drawings

[0020] To more clearly illustrate the embodiments of the present utility model, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0021] Figure 1 is the three-dimensional view of the aluminum row of the present utility model;

[0022] Figure 2 is the top view of the aluminum row of the present utility model;

[0023] Figure 3 is the cross-sectional view of the aluminum row of the present utility model;

[0024] Figure 4 is Figure 3 the partial enlarged view of the connection between the conductive ring and the aluminum row body in ;

[0025] Figure 5 is the exploded view of the aluminum row of the present utility model;

[0026] Figure 6 is Figure 5 the three-dimensional view of the aluminum row body in ;

[0027] Figure 7 is the top view of the aluminum row body;

[0028] Figure 8 is the cross-sectional view of the aluminum row body;

[0029] Figure 9 is Figure 5 the three-dimensional view of the conductive ring in ;

[0030] Figure 10 is the top view of the conductive ring;

[0031] Figure 11 is the cross-sectional view of the conductive ring.

[0032] Explanation of the reference numerals in the drawings:

[0033] 1 Conductive ring, 101 Round hole, 102 Polygonal hole, 2 Aluminum row body, 201 Step hole, 202 Insulating sheath. Specific embodiments

[0034] Next, the technical solutions in the embodiments of the present utility model will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present utility model. Obviously, the described embodiments are only a part of the embodiments of the present utility model, rather than all the embodiments. Based on the core concept of the present utility model and the following embodiments, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present utility model.

[0035] Embodiment 1, an aluminum busbar for vehicle current transmission, as Figure 1 and Figure 2 shown, includes an aluminum busbar body 2 with a through hole, and the through hole is connected to a conductive ring 1 by friction welding, and the reducibility of the material of the conductive ring 1 is greater than that of aluminum.

[0036] Specifically, the outer shape of the aluminum busbar body 2 is a sheet metal with a through hole made of aluminum. A conductive ring 1 is inserted into the through hole of the aluminum busbar body 2 to strengthen the hardness of the connection between the aluminum busbar body 2 and the terminal, and to prevent the aluminum busbar body 2 from deforming due to long-term extrusion, thereby avoiding torque attenuation of the connection structure between the aluminum busbar body 2 and the terminal; the reducibility of the material of the conductive ring 1 is greater than that of aluminum. After the aluminum busbar body 2 and the conductive ring 1 are connected by friction welding, molecular exchange occurs at the joint of the aluminum busbar body 2 and the conductive ring 1 to form an alloy, avoiding the electrochemical corrosion caused by the formation of a potential difference due to the direct connection of copper and aluminum.

[0037] Embodiment 2, an aluminum busbar for vehicle current transmission. On the basis of Embodiment 1, a plurality of through holes are provided in the through hole. The aluminum busbar body 2 is connected with a plurality of conductive rings 1 through the through holes. According to the connection requirements, one or more through holes are provided on the aluminum busbar body 2, and one or more conductive rings 1 are connected through the through holes and friction welding.

[0038] Embodiment 3, an aluminum busbar for vehicle current transmission. On the basis of Embodiment 2, as Figures 3 to 5 shown, the through hole is a stepped hole 201, and the conductive ring 1 is a stepped ring matching the stepped hole 201. The outer shape of the conductive ring 1 is a stepped cylinder. The small diameter section of the stepped ring matches the small hole of the stepped hole 201 on the aluminum busbar body 2, and the large diameter section of the stepped ring matches the large hole of the stepped hole 201 on the aluminum busbar body 2. The stepped hole 201 can increase the bonding surface between the aluminum busbar body 2 and the conductive ring 1, increase the contact area of friction welding, and improve the reliability of the connection.

[0039] Embodiment 4, an aluminum busbar for vehicle current transmission. On the basis of Embodiment 3, as Figures 9 to 11As shown, the conductive ring 1 is provided with a central hole, and the central hole includes a connected round hole 101 and a polygonal hole 102. The central hole is used to connect the terminal. The round hole 101 and the polygonal hole 102 are coaxial. The round hole 101 facilitates bolt connection, and the polygonal hole 102 facilitates fixture fixation of the conductive ring 1, which is convenient for friction welding.

[0040] Example 5, an aluminum bar for vehicle current transmission. On the basis of Example 4, as Figures 9 to 11 shown, the round hole 101 is arranged in the small-diameter section of the stepped ring, and the polygonal hole 102 is arranged in the large-diameter section of the stepped ring. During friction welding, the small-diameter section of the stepped ring is in the front, and the large-diameter section is in the back. The round hole 101 of the central hole is in the front, and the polygonal hole 102 is in the back. That is, when the aluminum bar body 2 and the conductive ring 1 are friction-welded, the axis of the central hole of the conductive ring 1 is aligned with the axis of the stepped hole 201 on the aluminum bar body 2, and the direction is small in the front and large in the back, that is, it is ensured that the small-diameter section is aligned with the round hole 101, and the large-diameter section is aligned with the polygonal hole 102.

[0041] Example 6, an aluminum bar for vehicle current transmission. On the basis of Example 5, as Figures 9 to 11 shown, the polygonal hole 102 is a regular polygonal hole, and the aperture of the regular polygonal hole is larger than the aperture of the round hole 101. The fixture of the welding machine can use the polygonal hole 102 to fix the conductive ring 1. The regular polygonal hole is more convenient for fixture fixation, and the aperture of the regular polygonal hole is larger than the aperture of the round hole 101, which is convenient for the bolt to pass through the conductive ring 1 for fixation.

[0042] Example 7, an aluminum bar for vehicle current transmission. On the basis of any one of Examples 1-6, as Figure 1 、 Figure 2 、 Figure 3 、 Figures 5 to 8 shown, the aluminum bar body 2 is connected with an insulating sheath 202, and the insulating sheath 202 is arranged at an interval from the through hole. The aluminum bar body 2 is a sheet metal made of aluminum plus an insulating material. The insulating material is preferably insulating rubber. The insulating material can be sleeved on the surface of the sheet metal or connected to the surface of the sheet metal by thermoforming. The insulating sheath 202 is used for insulation to improve safety.

[0043] Example 8, an aluminum bar for vehicle current transmission. On the basis of Example 7, the material of the conductive ring 1 is any one or more of copper, steel, zinc, and silver. Preferably, the material of the conductive ring 1 is copper. After the aluminum bar body 2 and the conductive ring 1 are friction-welded, molecular exchange occurs at the joint of the aluminum bar body 2 and the conductive ring 1 to form a copper-aluminum alloy, avoiding electrochemical corrosion caused by the formation of a potential difference due to the direct connection of copper and aluminum.

[0044] Example 9, an aluminum bar for vehicle current transmission. On the basis of Example 8, as Figure 3and Figure 4 As shown, the height of the conductive ring 1 is greater than the thickness of the aluminum busbar body 2. The height of the conductive ring 1 is H, and the thickness of the aluminum busbar body 2 is h. After being connected by friction welding, the end of the conductive ring 1 extends out of the aluminum busbar body 2, facilitating the connection between the conductive ring 1 and the terminal.

[0045] Embodiment 10, an aluminum busbar for vehicle current transmission. On the basis of Embodiment 9, as Figure 3 and Figure 4 shown, both end faces of the conductive ring 1 protrude from the surface of the aluminum busbar body 2. This facilitates the connection between the conductive ring 1 and the terminal and prevents the aluminum busbar body 2 from interfering with the connection between the terminal and the conductive ring 1.

[0046] When implementing Embodiment 10, first fix the aluminum busbar body 2 with a fixture, then fix the polygonal hole of the conductive ring 1 with a welding machine, and then insert the conductive ring 1 into the stepped hole of the aluminum busbar body 2. When inserting, the small-diameter section of the stepped ring matches the small hole of the stepped hole 201, and the large-diameter section of the stepped ring matches the large hole of the stepped hole 201. After insertion, ensure that both ends of the stepped ring protrude from both ends of the stepped hole 201. Finally, connect and fix the conductive ring 1 and the aluminum busbar body 2 by friction welding.

[0047] The details not elaborated in the present utility model are all well-known conventional technical means in the art.

[0048] The above content shows and describes the basic principle, main features and beneficial effects of the present utility model. The above is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. An aluminum busbar for vehicle current transmission, characterized in that: It comprises an aluminum bar body (2) with a through hole, wherein the through hole is connected to a conductive ring (1) by friction welding, and the conductive ring (1) is made of a material with a higher reducibility than aluminum.

2. The aluminum busbar for vehicle current transmission according to claim 1, characterized in that: There are a plurality of through holes.

3. The aluminum busbar for vehicle current transmission according to claim 2, characterized in that: The through hole is a stepped hole (201), and the conductive ring (1) is a stepped ring matching the stepped hole (201).

4. The aluminum busbar for vehicle current transmission according to claim 3, characterized in that: The conductive ring (1) is provided with a central hole, which comprises a circular hole (101) and a polygonal hole (102) that are connected.

5. The aluminum busbar for vehicle current transmission according to claim 4, characterized in that: The circular hole (101) is provided in the small diameter section of the step ring, and the polygonal hole (102) is provided in the large diameter section of the step ring.

6. The aluminum busbar for vehicle current transmission according to claim 5, characterized in that: The polygonal hole (102) is a regular polygonal hole, and the diameter of the regular polygonal hole is larger than the diameter of the circular hole (101).

7. The aluminum busbar for vehicle current transmission according to any one of claims 1 to 6, characterized in that: The aluminum bar body (2) is connected to an insulating sheath (202), and the insulating sheath (202) is spaced apart from the through hole.

8. The aluminum busbar for vehicle current transmission according to claim 7, characterized in that: The conductive ring (1) is made of any one or more of copper, steel, zinc and silver.

9. The aluminum busbar for vehicle current transmission according to claim 8, characterized in that: The height of the conductive ring (1) is greater than the thickness of the aluminum bar body (2).

10. The aluminum busbar for vehicle current transmission according to claim 9, characterized in that: Both end surfaces of the conductive ring (1) protrude from the surface of the aluminum bar body (2).

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