Charging busbar ultrasonic welding terminal reinforcing structure

Abstract

The utility model discloses a charging busbar ultrasonic welding terminal reinforcing structure, which comprises a busbar terminal and a plug-in terminal, one end of the busbar terminal is provided with a busbar end, the busbar end is provided with lower holes distributed in a rectangular manner, one end of the plug-in terminal is provided with a plug-in end, and the plug-in end is provided with an upper hole distributed in a rectangular manner. The plug-in terminal is provided with upper holes distributed corresponding to the lower holes, and the busbar terminal and the plug-in terminal are fixed through a fastener. After the ultrasonic welding is finished, the lower rivet passes through the lower hole and the upper hole of the busbar end, the upper rivet is inserted into the lower rivet from top to bottom, and the upper rivet and the lower rivet reinforce the welding surface together in a pressing rivet mode. The technical problems that when a copper bar and an aluminum bar are welded through traditional ultrasonic waves, due to the fact that the surface hardness of the copper bar and the aluminum bar is high, the fusion effect between molecular layers formed by mutual friction between the copper bar and the aluminum bar is not good enough during ultrasonic welding, the welding tearing force is small, and the welding face is prone to falling off are solved.

Description

Technical Field

[0001] This utility model belongs to the field of ultrasonic welding technology, specifically relating to a reinforcement structure for ultrasonic welding terminals of a charging busbar. Background Technology

[0002] Ultrasonic welding utilizes high-frequency vibration waves transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other, forming a fusion between molecular layers.

[0003] In power transmission systems, traditional cables and terminals are joined using ultrasonic welding. Because the cable conductors are made of flexible copper or aluminum wire, the friction between the conductor and the terminal surface easily leads to molecular fusion, resulting in a strong weld. However, in power transmission systems using aluminum and copper busbars, the higher surface hardness of copper and aluminum means that traditional resistance welding causes spatter and oxidation, damaging the surfaces and increasing the weld resistance. Furthermore, the fusion between the molecular layers formed by the friction between the copper and aluminum busbars is insufficient, resulting in weak tear resistance and a tendency for the weld to detach. Utility Model Content

[0004] The purpose of this utility model is to provide a reinforcement structure for ultrasonic welding terminals of charging busbars, so as to solve the problem mentioned in the background art that the copper busbars and aluminum busbars have high surface hardness and the fusion effect is not good.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a charging busbar ultrasonic welding terminal reinforcement structure, comprising a busbar terminal and a plug-in terminal, wherein one end of the busbar terminal is provided with a busbar end head, and the busbar end head is provided with rectangularly distributed lower holes; one end of the plug-in terminal is provided with a plug-in end head, and the plug-in end head is provided with upper holes corresponding to the lower holes; the busbar terminal and the plug-in terminal are fixed by fasteners, wherein the fasteners are rivets with mushroom-shaped structures at both ends.

[0006] Preferably, the fastener is integrally formed by pressing the upper and lower parts of the mold together.

[0007] Preferably, the fastener includes a lower rivet that passes through the lower hole and the upper hole from bottom to top, and an upper rivet that is inserted into the lower rivet from top to bottom by riveting.

[0008] Preferably, the lower rivet comprises a hollow tube, the bottom of which is provided with a semi-circular and flat-bottomed lower rivet cap, and the top of which is provided with a ring of plastic elastic pieces.

[0009] Preferably, the diameter of the hollow tube is smaller than that of the lower hole and the upper hole, and the diameter of the lower nail cap is larger than that of the lower hole.

[0010] Preferably, the upper rivet includes a large column section, the top of which is provided with a semi-circular upper rivet head, and the bottom of which is provided with a small column section.

[0011] Preferably, the large column segment is interference-fitted with the hollow tube, and the small column segment is clearance-fitted with the hollow tube.

[0012] Preferably, the diameter of the upper nail cap is larger than the diameter of the upper hole.

[0013] Preferably, the busbar end is provided with a groove, and the groove outline shape is adapted to the shape of the plug-in end.

[0014] Preferably, when the plug-in terminal is placed in the groove of the busbar terminal, a gap is left between the plug-in terminal and the busbar terminal in the lateral direction, which is necessary for the high-frequency vibration of ultrasonic welding.

[0015] Compared with the prior art, this utility model provides a reinforcement structure for ultrasonic welding terminals of charging busbars, which has the following beneficial effects:

[0016] 1. This utility model solves the technical problems of insufficient fusion effect between molecular layers formed by mutual friction between copper and aluminum busbars during ultrasonic welding, low welding tear force, and easy detachment of welded surfaces when ultrasonic welding is used to weld the busbar ends and plug-in ends after drilling holes in the surface of the busbar terminals and plug-in terminals. After ultrasonic welding, the lower rivet passes through the lower hole and upper hole of the busbar end, and the upper rivet is inserted into the lower rivet from top to bottom. The upper rivet and the lower rivet are reinforced together by pressing.

[0017] 2. In the process of using a press-fitting method to reinforce the welding surfaces of the upper and lower rivets together, since the diameter of the upper rivet head is larger than the diameter of the upper hole, the plastic elastic sheet can be expanded and compressed on the upper surface of the plug-in terminal by the compression of the upper rivet head. The small column segment is inserted into the hollow tube and the large column segment is introduced into the hollow tube. By the compression of the large column segment, the hollow tube expands outward into the lower hole and the upper hole, thereby further improving the stability of the welding surfaces of the upper and lower rivets. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0019] Figure 1This is a schematic diagram of the fastener proposed in this utility model before it is used for riveting the busbar terminal and the plug terminal;

[0020] Figure 2 This is a schematic diagram of the fastener proposed in this utility model after it is used to rivet the busbar terminal and the plug terminal;

[0021] Figure 3 This is an exploded view of the fastener, busbar terminal, and plug-in terminal proposed in this utility model.

[0022] Figure 4 This is a schematic cross-sectional view of the fastener before riveting proposed in this utility model;

[0023] Figure 5 This is a schematic cross-sectional view of the fastener after pressing and riveting according to this utility model;

[0024] In the diagram: 1. Busbar terminal; 11. Busbar end; 12. Lower hole; 2. Plug-in terminal; 21. Plug-in end; 22. Upper hole; 3. Fastener; 31. Lower rivet; 311. Hollow tube; 312. Lower rivet cap; 313. Plastic spring; 32. Upper rivet; 321. Large column section; 322. Upper rivet cap; 323. Small column section. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] Example 1

[0027] Please see Figure 1 , Figure 2 and Figure 3This utility model provides a technical solution: a charging busbar ultrasonic welding terminal reinforcement structure, including a busbar terminal 1 and a plug-in terminal 2. One end of the busbar terminal 1 is provided with a busbar end head 11, which is an aluminum busbar. The busbar end head 11 has rectangularly distributed lower holes 12. One end of the plug-in terminal 2 is provided with a plug-in end head 21, which is a copper busbar. The plug-in end head 21 has upper holes 22 corresponding to the lower holes 12. The busbar terminal 1 and the plug-in terminal 2 are fixed by fasteners 3, which are rivets with mushroom-shaped structures at both ends. The fasteners 3 are pressed together by a mold. The body is formed by molding. When welding the busbar terminal 1 and the plug-in terminal 2, holes are drilled on the surface of the busbar end 11 and the plug-in terminal 21 of the busbar terminal 1 and the plug-in terminal 2 for ultrasonic welding. After ultrasonic welding, rivets 32 and lower rivets 31 are added to strengthen the welding surface. Then, the busbar end 11 and the plug-in terminal 21 after drilling are welded using an ultrasonic welding machine. After ultrasonic welding is completed, the lower rivet 31 is passed through the lower hole 12 and the upper hole 22 of the busbar end 11. Then, the upper rivet 32 ​​is inserted into the lower rivet 31 from top to bottom, and the upper rivet 32 ​​and the lower rivet 31 are reinforced together by pressing.

[0028] Please see Figure 4 and Figure 5 The fastener 3 includes a lower rivet 31 that passes through the lower hole 12 and the upper hole 22 from bottom to top, and an upper rivet 32 ​​that is inserted into the lower rivet 31 from top to bottom by riveting. The lower rivet 31 includes a hollow tube 311. The bottom of the hollow tube 311 is provided with a semi-circular and flat lower rivet cap 312. The top of the hollow tube 311 is provided with a ring of plastic elastic pieces 313. It should be noted that the diameter of the hollow tube 311 is smaller than that of the lower hole 12 and the upper hole 22, so that the hollow tube 311 can pass through the lower hole 12 and the upper hole 22 from bottom to top. The diameter of the lower rivet cap 312 is larger than that of the lower hole 12, so that the lower rivet cap 312 cannot pass through the lower hole 12 and abuts against the surface of the busbar end 11.

[0029] Please see Figure 4 and Figure 5The upper rivet 32 ​​includes a large column section 321, with a semi-circular upper rivet head 322 at the top of the large column section 321. The upper rivet head 322 becomes flat after pressing. A small column section 323 is provided at the bottom of the large column section 321. Specifically, the large column section 321 has an interference fit with the hollow tube 311, and the small column section 323 has a clearance fit with the hollow tube 311. During the process of reinforcing the welded surfaces of the upper rivet 32 ​​and the lower rivet 31 together by press riveting, due to… The diameter of the upper rivet cap 322 is larger than the diameter of the upper hole 22. Under the pressure of the upper rivet cap 322, the plastic elastic piece 313 can expand and compress on the upper surface of the plug-in terminal 21. The small column segment 323 is inserted into the hollow tube 311 and the large column segment 321 is introduced into the hollow tube 311. Under the pressure of the large column segment 321, the hollow tube 311 expands outward between the lower hole 12 and the upper hole 22, so as to achieve a stable connection between the welding surfaces of the upper rivet 32 ​​and the lower rivet 31.

[0030] Furthermore, the busbar end 11 is provided with a groove, and the outline of the groove is adapted to the shape of the plug-in end 21, so that the plug-in end 21 can be placed in the groove of the busbar end 11 to play a fixing role. The depth of the groove is less than the thickness of the plug-in end 21, which facilitates subsequent pressing. When the plug-in end 21 is placed in the groove of the busbar end 11, there is a gap between the plug-in end 21 and the busbar end 11 on the side, which is necessary for the high-frequency vibration of ultrasonic welding.

[0031] Furthermore, the flat bottom design of the lower rivet 31 cap 312 makes it easier to place the lower rivet 31 stably and prevent it from shaking during riveting. The semi-circular mushroom-shaped design of the upper rivet cap 322 on the top of the large column section 321 requires less pressing force compared to the flat design, making it easier to press and form.

[0032] Example 2

[0033] Unlike Embodiment 1, fastener 3 is a single T-shaped rivet. When welding busbar terminal 1 and plug-in terminal 2, holes are first drilled on the surfaces of the busbar end 11 and plug-in end 21 of busbar terminal 1 and plug-in terminal 2. After ultrasonic welding, rivet 32 ​​and lower rivet 31 are added to reinforce the welding surface. Then, an ultrasonic welding machine is used to weld the drilled busbar end 11 and plug-in end 21. After ultrasonic welding is completed, a rivet with a T-shaped structure is used... With the larger end at the bottom and the smaller end at the top, the rivet passes through the lower hole 12 and the upper hole 22 of the busbar end 11 from bottom to top. The smaller end of the rivet with the T-shaped structure extends beyond the upper hole 22 by a certain distance. Then, using a concave arc-shaped mold, the columnar part of the rivet with the T-shaped structure that extends beyond the upper hole 22 is pressed into an arc-shaped mushroom shape from top to bottom by a pressing riveting method. This mushroom shape is then matched with the larger end of the T-shaped rivet to reinforce the busbar end 11 and the plug-in end 21 together.

[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A charging busbar ultrasonic welding terminal reinforcement structure, comprising busbar terminals (1) and plug-in terminals (2), characterized in that: One end of the busbar terminal (1) is provided with a busbar end head (11), and the busbar end head (11) is provided with a rectangularly distributed lower hole (12). One end of the plug-in terminal (2) is provided with a plug-in end head (21), and the plug-in end head (21) is provided with an upper hole (22) corresponding to the lower hole (12). The busbar terminal (1) and the plug-in terminal (2) are fixed by fasteners (3), and the fasteners (3) are rivets with mushroom-shaped structures at both ends.

2. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 1, characterized in that: The fastener (3) is formed by pressing the upper and lower parts of the mold together as one piece.

3. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 1, characterized in that: The fastener (3) includes a lower rivet (31) that passes through the lower hole (12) and the upper hole (22) from bottom to top, and an upper rivet (32) that is inserted into the lower rivet (31) from top to bottom by riveting.

4. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 3, characterized in that: The lower rivet (31) includes a hollow tube (311), the bottom of which is provided with a semi-circular and flat lower rivet cap (312), and the top of which is provided with a ring of plastic elastic pieces (313).

5. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 4, characterized in that: The diameter of the hollow tube (311) is smaller than that of the lower hole (12) and the upper hole (22), and the diameter of the lower nail cap (312) is larger than that of the lower hole (12).

6. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 5, characterized in that: The upper rivet (32) includes a large column section (321), the top of which is provided with a semi-circular upper rivet head (322), and the bottom of which is provided with a small column section (323).

7. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 6, characterized in that: The large column section (321) is interference-fitted with the hollow tube (311), and the small column section (323) is clearance-fitted with the hollow tube (311).

8. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 7, characterized in that: The diameter of the upper nail cap (322) is larger than the diameter of the upper hole (22).

9. A charging busbar ultrasonic welding terminal reinforcement structure according to any one of claims 1-8, characterized in that: The busbar end (11) is provided with a groove, and the shape of the groove is adapted to the shape of the plug-in end (21).

10. The ultrasonic welding terminal reinforcement structure for a charging busbar according to claim 9, characterized in that: When the plug-in terminal (21) is placed in the groove of the busbar terminal (11), a gap is left between the plug-in terminal (21) and the busbar terminal (11) on the side for the high-frequency vibration of ultrasonic welding.

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