Electric connector
By using friction stir welding of aluminum flat wires with conductive devices, the problems of heavy wire harness weight and high cost were solved, achieving a lightweight and robust electrical connection structure.
Patent Information
- Application Number
- CN202422472428.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-12
- Publication Date
- 2025-12-12
- Estimated Expiration
- 2034-10-12
AI Technical Summary
Existing wiring harnesses using copper wires result in high weight and cost, necessitating a lightweight electrical connection structure.
Aluminum flat wire and conductive device are connected by friction stir welding. One end of the conductive device is inserted into the connection hole of the aluminum flat wire and welded by friction stir welding. The connection hole and the conductive device are either clearance fit or welded.
It achieves lightweight, environmentally friendly, and robust electrical connections, meeting the manufacturing requirements of wire harness products.
Smart Images
Figure CN223665667U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to the technical field of electric connection, more particularly to an electric connector. BACKGROUND
[0002] At present, the basic copper wire is used in the wire harness, and with the increasingly urgent global energy saving and environmental protection, the lightweight research of the wire harness becomes the future development direction. Because the copper material has large density and high price, the unit volume of the copper material is much heavier than that of the aluminum material, and the price is also much higher, so the design of the terminal needs to reduce the use of the copper material as much as possible.
[0003] Therefore, a new structure is needed to solve the above problems. CONTENT OF THE UTILITY MODEL
[0004] The utility model discloses a kind of electric connectors, including aluminum flat wire, connection hole is set on the aluminum flat wire, electrically conductive device, one end of the electrically conductive device is inserted into the connection hole, and the aluminum flat wire and the end of the electrically conductive device are connected by friction stir welding mode welding.
[0005] Optionally, the electrically conductive device includes fixed part and connecting part, a step surface is provided between the fixed part and the connecting part, the fixed part is inserted into the connection hole, and the step surface is in abutment with the end surface of the aluminum flat wire.
[0006] Optionally, the outer circumferential surface of the fixed part and the inner circumferential surface of the connection hole are gap fit connected.
[0007] Optionally, the connection hole is a blind hole, and the bottom wall of at least part of the blind hole and the end of the fixed part are connected by friction stir welding mode welding.
[0008] Optionally, the connection hole is a through hole, the end of the fixed part is flush with the end surface of the connection hole, or the end of the fixed part is higher than the end surface of the connection hole, and at least part of the end of the fixed part and the end surface of the connection hole are connected by friction stir welding mode welding.
[0009] Optionally, the axis of the fixed part and the extension direction of the end of the aluminum flat wire are at a set angle.
[0010] Optionally, the connection hole is arranged in the thickness direction of the aluminum flat wire, and the depth of the friction stir welding is at least 2 / 3 of the thickness of the aluminum flat wire.
[0011] Optionally, after the fixed part and the aluminum flat wire are welded, the step surface and the end surface of the aluminum flat wire are continuously welded, so that the connecting part and the aluminum flat wire are connected by friction stir welding mode welding.
[0012] Optionally, the material of the conductive device is one of copper or copper alloy, aluminum or aluminum alloy.
[0013] Optionally, the material of the conductive device is different from the material of the aluminum flat wire.
[0014] The utility model has the following technical effects:
[0015] The novel structure is efficient, environmentally friendly, firmly connected, and has excellent product performance, and meets the manufacturing requirements of lightweight wire harness products.
[0016] Other features and advantages of the utility model will become apparent from the following detailed description of exemplary embodiments thereof, with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS
[0017] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the utility model and, together with the description, serve to explain the principles of the utility model.
[0018] Figure 1 Figure 1 is a schematic view of the cooperation structure of the aluminum flat wire and the conductive device of the utility model;
[0019] Figure 2 Figure 2 is a schematic view of the overall structure of the electrical connector;
[0020] Figure 3 Figure 3 is another schematic view of the conductive device.
[0021] The figures are marked as follows:
[0022] 10, aluminum flat wire; 11, connecting hole;
[0023] 20, conductive device; 21, fixed part; 22, connecting part; 23, step surface. DETAILED DESCRIPTION
[0024] Various exemplary embodiments of the utility model will now be described in detail with reference to the accompanying drawings. It should be noted that: unless otherwise specifically stated, the relative arrangement, numerical expression and numerical value of the components and steps set forth in these embodiments do not limit the scope of the utility model.
[0025] The following description of at least one exemplary embodiment is merely illustrative in nature and in no way limits the utility model and its applications or uses.
[0026] Techniques, methods, and devices known to those of ordinary skill in the relevant art can not be discussed in detail, but should be considered part of the specification when appropriate.
[0027] In all the examples shown and discussed herein, any specific values should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.
[0028] Example 1
[0029] like Figures 1-2 The electrical connector shown includes an aluminum flat wire 10 with a connection hole 11 and a conductive device 20. One end of the conductive device 20 is inserted into the connection hole 11. The aluminum flat wire 10 and the end of the conductive device 20 are welded together by friction stir welding. The outer peripheral surface of the conductive device 20 is clearance-fitted with the aluminum flat wire 10.
[0030] In one embodiment, the connection hole 11 is a blind hole, and at least part of the bottom wall of the blind hole and the end of the conductive device 20 are welded together by friction stir welding.
[0031] In another embodiment, the connecting hole 11 is a through hole, the end of the conductive device 20 is flush with the end face of the connecting hole 11, or the end of the conductive device 20 is higher than the end face of the connecting hole 11, and at least part of the end of the conductive device 20 is welded to the end face of the connecting hole 11 by friction stir welding.
[0032] In the specific implementation process, the conductive device 20 is cylindrical. A mold is used to fix the conductive device 20, and then the connecting hole 11 of the aluminum flat wire 10 is fitted onto the conductive device 20. The stirring needle starts to stir along the gap between the conductive device 20 and the aluminum flat wire 10 and rotates and stirs towards the center of the conductive device 20 for welding. Finally, the needle is withdrawn at the center position of the upper surface of the conductive device 20. The stirring needle fully stirs the conductive device 20 and the aluminum flat wire 10. After welding is completed, the burrs on the welded surface are further removed.
[0033] To verify the welding strength between the conductive device 20 and the aluminum flat wire 10 after welding, the inventors used 10 identical sets of aluminum flat wires 10 and conductive devices 20 for experimental measurement. Specifically, the aluminum flat wire 10 used 3mm thick aluminum busbars, and the conductive device 20 used cylindrical aluminum terminals with a diameter of 12mm. The two were welded using a friction stir welding method.
[0034] The specific test method is as follows: use a torque of 20 Nm to fix the conductive device 20 of the sample on a special tooling, connect the two measuring points of the digital multimeter to the flat terminal and the cylindrical terminal respectively, and measure the resistance value after the current of 100 A is stabilized.
[0035] Then select the appropriate fixture, both ends of the conductive device 20 clamped on the universal material testing machine, along the axis of the conductive device 20, at a speed of 100 mm / min, record the conductive device 20 and aluminum flat wire 10 two separation force value, that is, the test required pulling force. Contact resistance <0.02 mΩ, pulling force > 3500N is qualified.
[0036] As shown in Table 1: the contact resistance and pulling force of the conductive device and the aluminum flat wire after welding
[0037]
[0038] From Table 1, it can be seen that the mechanical properties of the welding can meet the requirements. The new structure is efficient, environmentally friendly, firmly connected, and has excellent product performance, meeting the manufacturing needs of lightweight wire harness products.
[0039] In a preferred embodiment, according to the actual application, the axis of the conductive device 20 is at a set angle to the extension direction of the end of the aluminum flat wire 10. It can be 30°, 60°, 90° or 120°, etc. Preferably, the axis of the conductive device 20 is perpendicular to the extension direction of the end of the aluminum flat wire 10.
[0040] In an embodiment, the connecting hole 11 is arranged in the thickness direction of the aluminum flat wire 10. In order to ensure the welding strength between the aluminum flat wire 10 and the conductive device 20, the depth of the friction stir welding is at least 2 / 3 of the thickness of the aluminum flat wire 10.
[0041] In a specific application, the material of the conductive device 20 is one of copper or copper alloy, aluminum or aluminum alloy.
[0042] The material of the conductive device 20 is the same as or different from the material of the aluminum flat wire 10.
[0043] Example 2, the difference between this embodiment and example 1 is only the following scheme.
[0044] As shown in Table 1: the contact resistance and pulling force of the conductive device and the aluminum flat wire after welding Figure 3 The conductive device 20 includes a fixed part 21 and a connecting part 22, a step surface 23 is arranged between the fixed part 21 and the connecting part 22, the fixed part 21 is inserted into the connecting hole 11, and the step surface 23 abuts against the end surface of the aluminum flat wire 10.
[0045] The outer circumferential surface of the fixed part 21 and the inner circumferential surface of the connecting hole 11 are connected by gap fit.
[0046] In an embodiment, the connecting hole 11 is a blind hole, and at least part of the bottom wall of the blind hole and the end of the fixed part 21 are connected by friction stir welding.
[0047] Alternatively, the connecting hole 11 is a through hole, the end of the fixing part 21 is flush with the end surface of the connecting hole 11, or the end of the fixing part 21 is higher than the end surface of the connecting hole 11, and at least part of the end of the fixing part 21 is welded and connected with the end surface of the connecting hole 11 by means of friction stir welding.
[0048] In this embodiment, after the fixing part 21 is welded with the aluminum flat wire 10, in order to further ensure the connection stability between the conductive device 20 and the aluminum flat wire 10, the stepped surface 23 and the end surface of the aluminum flat wire 10 are continuously welded, so that the connecting part 22 and the aluminum flat wire 10 are welded and connected by means of friction stir welding.
[0049] Although some specific embodiments of the present application have been described in detail by examples, those skilled in the art should understand that the above examples are only for illustration, but not for limiting the scope of the present application. Those skilled in the art should understand that the above embodiments can be modified without departing from the scope and spirit of the present application. The scope of the present application is defined by the appended claims.
Claims
1. An electrical connector, characterized in that, Includes aluminum flat wire, wherein the aluminum flat wire has a connecting hole. A conductive device, one end of which is inserted into the connecting hole, the conductive device includes a fixing part and a connecting part, a stepped surface is provided between the fixing part and the connecting part, the fixing part is inserted into the connecting hole, the stepped surface abuts against the end face of the aluminum flat wire, and the aluminum flat wire is welded to the end of the fixing part by friction stir welding; the axis of the fixing part is at a set angle to the extension direction of the end of the aluminum flat wire.
2. The electrical connector according to claim 1, characterized in that, The outer peripheral surface of the fixing part and the inner peripheral surface of the connecting hole are connected by a clearance fit.
3. The electrical connector according to claim 1, characterized in that, The connecting hole is a blind hole, and at least part of the bottom wall of the blind hole and the end of the fixing part are welded together by friction stir welding.
4. The electrical connector according to claim 1, characterized in that, The connecting hole is a through hole, the end of the fixing part is flush with the end face of the connecting hole, or the end of the fixing part is higher than the end face of the connecting hole, and at least part of the end of the fixing part is welded to the end face of the connecting hole by friction stir welding.
5. The electrical connector according to claim 1, characterized in that, The connecting hole is provided in the thickness direction of the aluminum flat wire, and the depth of the friction stir welding is at least 2 / 3 of the thickness of the aluminum flat wire.
6. The electrical connector according to claim 1, characterized in that, After the fixing part is welded to the aluminum flat wire, the stepped surface and the end face of the aluminum flat wire are further welded together so that the connecting part is welded to the aluminum flat wire by friction stir welding.
7. The electrical connector according to claim 1, characterized in that, The conductive device is made of one of the following materials: copper or copper alloy, aluminum or aluminum alloy.
8. The electrical connector according to claim 7, characterized in that, The conductive device is made of a different material than the aluminum flat wire.