Laser welding process high-voltage box with high breaking capacity

Abstract

The utility model discloses a laser welding process high-voltage box with high breaking capacity, which belongs to the technical field of high-voltage power distribution and comprises a shell, a conducting bar and an electric control device. The conducting bar is arranged in the shell and is provided with a connecting hole; the electric control device is arranged in the shell and comprises a first contact and a second contact, the first contact comprises an external connection terminal and a tellurium copper terminal, and the external connection terminal is connected with the tellurium copper terminal; the external connection terminal is at least partially arranged in the connection hole and is in laser welding with the conducting bar; and the tellurium copper terminal is connected with the second contact. The first contact is divided into the external connection terminal and the tellurium copper terminal, the external connection terminal is used for being connected with the outside, and the tellurium copper terminal is used for being connected with the second contact; the external connection terminal can be designed according to the material of the external conducting bar so as to ensure the electrical connection performance of the static contact and the external conducting bar; the tellurium copper terminal piece is connected with the second contact through tellurium copper, the tellurium copper has higher corrosion resistance and strength compared with pure copper, and the large-current breaking capacity between the contacts can be improved.

Description

Technical Field

[0001] This application belongs to the field of high-voltage power distribution technology, specifically relating to a high-voltage box using laser welding process with high breaking capacity. Background Technology

[0002] In a vehicle's battery module, high-voltage power distribution equipment such as BDU (Battery Disconnect Unit), PDU (Power Distribution Unit), and BMU (Battery Management Unit) are typically required to manage the power distribution of the battery.

[0003] In the aforementioned high-voltage power distribution equipment, circuit breaking and control are typically achieved through electrical control devices such as circuit breakers, relays, contactors, switchgear, and overload protectors. Among these, moving and stationary contacts are key components for controlling circuit connection and disconnection. The moving contact is the movable contact portion; when the drive mechanism operates, the moving contact moves accordingly, thereby changing the contact state with the stationary contact and thus connecting or disconnecting the circuit. The stationary contact is the fixed contact portion, maintaining its position and providing a relatively stable contact object for the moving contact, working together to complete the circuit connection and disconnection operation.

[0004] To accommodate the electrical connection performance between electronic control devices and external busbars, stationary contacts are often made using the same material as the external busbars (e.g., pure copper). However, the corrosion resistance and strength requirements of the stationary contacts are often overlooked. This results in the stationary contacts being easily corroded during repeated, high-frequency breaking operations, which reduces the high-current breaking capacity of the electronic control devices and affects their performance. Utility Model Content

[0005] Purpose of the utility model: This application develops a high-voltage box for laser welding process with high breaking capacity, aiming to solve the technical problem of low high-current breaking capacity of electrical control devices in the prior art.

[0006] Technical solution: Embodiments of this application provide a high-voltage box for laser welding processes with high breaking capacity, comprising:

[0007] case;

[0008] A conductive busbar is disposed in the housing and has connection holes;

[0009] An electronic control device is disposed in the housing. The electronic control device includes a first contact and a second contact. The first contact includes an external terminal and a tellurium copper terminal. The external terminal is at least partially disposed in the connection hole and laser-welded to the busbar. The tellurium copper terminal is connected to the second contact.

[0010] In some embodiments, the tellurium copper terminal has a connecting groove, the opening of which faces the external terminal;

[0011] The external terminal includes a first connecting platform, which is disposed on the side of the external terminal near the tellurium copper terminal. The first connecting platform is at least partially disposed in the connecting groove to connect the external terminal and the tellurium copper terminal.

[0012] In some embodiments, along the arrangement direction of the tellurium copper terminal and the external connection terminal, the tellurium copper terminal has a minimum length b mm, satisfying: 5 ≤ b.

[0013] In some embodiments, the external terminal further includes a second connecting platform, which is disposed on the side of the external terminal away from the tellurium copper terminal;

[0014] Along the arrangement direction of the tellurium copper terminal and the external connection terminal, the second connection platform has a minimum length amm, satisfying: 2≤a≤5.

[0015] In some embodiments, a=2.5, a=3, or a=4.

[0016] In some embodiments, the external terminal and the tellurium copper terminal are brazed together.

[0017] In some embodiments, the first connecting platform and the connecting groove are connected by filler wire welding.

[0018] In some embodiments, the external terminal is a pure copper terminal or a pure aluminum terminal.

[0019] In some embodiments, the conductive busbar is a pure copper conductive busbar or a pure aluminum conductive busbar.

[0020] In some embodiments, the electrical control device is a circuit breaker, relay, contactor, switchgear, overload protector, precharge module, or capacitor, and the first contact is a stationary contact and the second contact is a moving contact.

[0021] Beneficial Effects: Compared with the prior art, the high-voltage box with high breaking capacity laser welding process provided in this application includes a shell, a conductive bus, and an electrical control device. The conductive bus is disposed in the shell and has a connection hole. The electrical control device is disposed in the shell and includes a first contact and a second contact. The first contact includes an external terminal and a tellurium copper terminal, which are connected. The external terminal is at least partially disposed in the connection hole and laser welded to the conductive bus to realize the electrical connection between the electrical control device and other electrical components. The tellurium copper terminal is connected to the second contact. This application divides the first contact into two parts: an external terminal and a tellurium copper terminal. The external terminal is used to connect to the outside, and the tellurium copper terminal is used to connect to the second contact. The external terminal can be designed according to the material of the external conductive bus to ensure the electrical connection performance between the stationary contact and the external conductive bus. The tellurium copper terminal is made of tellurium copper and connected to the second contact. Tellurium copper has higher corrosion resistance and strength than pure copper, which can improve the high current breaking capacity between the contacts. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 A structural cross-sectional view of an embodiment of a high-voltage box with high breaking capacity laser welding process provided in this application, in which external terminals and tellurium terminals are connected by filler wire welding using a first connecting platform and connecting groove;

[0024] Figure 2 for Figure 1 Cross-sectional view of the internal and external connectors;

[0025] Figure 3 for Figure 1 Cross-sectional view of the tellurium copper terminal;

[0026] Figure 4 A front view of an embodiment of a high-voltage box with high breaking capacity laser welding process provided in this application, in which external terminals and tellurium copper terminals are brazed together using a first connecting surface and a second connecting surface;

[0027] Figure 5 for Figure 4 Front view of the internal and external connector terminals;

[0028] Figure 6 for Figure 4 Front view of the tellurium copper terminal;

[0029] Reference numerals: 10, external terminal; 11, first connecting platform; 12, second connecting platform; 13, first connecting surface; 20, tellurium copper terminal; 22, connecting groove; 23, second connecting surface; X, first direction. Detailed Implementation

[0030] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0031] In a vehicle's battery module, high-voltage power distribution equipment such as BDU (Battery Disconnect Unit), PDU (Power Distribution Unit), and BMU (Battery Management Unit) are typically required to manage the power distribution of the battery.

[0032] In the aforementioned high-voltage power distribution equipment, circuit breaking and control are typically achieved through electrical control devices such as circuit breakers, relays, contactors, switchgear, and overload protectors. Among these, moving and stationary contacts are key components for controlling circuit connection and disconnection. The moving contact is the movable contact portion; when the drive mechanism operates, the moving contact moves accordingly, thereby changing the contact state with the stationary contact and thus connecting or disconnecting the circuit. The stationary contact is the fixed contact portion, maintaining its position and providing a relatively stable contact object for the moving contact, working together to complete the circuit connection and disconnection operation.

[0033] To accommodate the electrical connection performance between electronic control devices and external busbars, stationary contacts are often made using the same material as the external busbars (e.g., pure copper). However, the corrosion resistance and strength requirements of the stationary contacts are often overlooked. This results in the stationary contacts being easily corroded during repeated, high-frequency breaking operations, which reduces the high-current breaking capacity of the electronic control devices and affects their performance.

[0034] In view of this, embodiments of this application provide a high-voltage box for laser welding process with high breaking capacity, including a housing, a busbar, and an electrical control device; the busbar is disposed in the housing and has a connection hole; the electrical control device is disposed in the housing and includes a first contact and a second contact, the first contact including an external terminal 10 and a tellurium copper terminal 20, the external terminal 10 and the tellurium copper terminal 20 being connected; the external terminal 10 is at least partially disposed in the connection hole and laser welded to the busbar to realize the electrical connection of the electrical control device with other electrical components; the tellurium copper terminal 20 is connected to the second contact. This application divides the first contact into two parts: an external terminal 10 and a tellurium copper terminal 20. The external terminal 10 is used to connect to the outside, and the tellurium copper terminal 20 is used to connect to the second contact. The external terminal 10 can be designed according to the material of the external conductive bus to ensure the electrical connection performance between the stationary contact and the external conductive bus. The tellurium copper terminal 20 is made of tellurium copper and is connected to the second contact. Tellurium copper has higher corrosion resistance and strength than pure copper, which can improve the high current breaking capacity between the contacts.

[0035] In some embodiments, please refer to Figure 1 and Figure 4 , Figure 1 This is a structural cross-sectional view of an embodiment of a high-voltage box using a high-breaking-capacity laser welding process, where external terminals 10 and tellurium terminals 20 are connected by filler wire welding via a first connecting platform 11 and a connecting groove 22. Figure 4 This is a front view of an embodiment of a high-voltage box with high breaking capacity laser welding process provided in this application, in which the external terminal 10 and the tellurium copper terminal 20 are brazed together using a first connecting surface 13 and a second connecting surface 23. The first contact provided in this application embodiment is a combined cylindrical workpiece, with the axes of multiple cylinders coinciding and the multiple cylinders arranged along the axial direction. It can be understood that the axis of the multiple cylinders coinciding is the straight line of the first direction X, and the first direction X is the arrangement direction of the external terminal 10 and the tellurium copper terminal 20.

[0036] In some embodiments, the high-voltage box with high breaking capacity laser welding process provided in this application can be a high-voltage power distribution device such as a BDU (Battery Disconnect Unit), PDU (Power Distribution Unit), or BMU (Battery Management Unit), and its housing is an integrally molded injection molded part. The housing has a mounting groove for mounting electrical control devices, and a through hole is provided at the bottom of the mounting groove; the conductive bus is integrally injection molded with the housing, and the conductive bus is at least partially disposed in the through hole so that the conductive bus can be connected to the electrical control devices. Specifically, the portion of the conductive bus disposed in the through hole is provided with a connection hole, and the external terminal 10 is at least partially disposed in the connection hole and laser welded to the conductive bus.

[0037] In some embodiments, the external terminal 10 is a pure copper terminal or a pure aluminum terminal, and the conductive bus is a pure copper conductive bus or a pure aluminum conductive bus. For example, when the conductive bus used to connect the electronic control device in the BDU (Battery Distribution Unit) is a pure copper conductive bus, the external terminal 10 is a pure copper terminal; when the conductive bus used to connect the electronic control device in the BDU is a pure aluminum conductive bus, the external terminal 10 is a pure aluminum terminal. It can be understood that when manufacturing or selecting the external terminal 10 in this application, the material of the external terminal 10 is determined according to the material of the conductive bus. The material of the conductive bus and the material of the external terminal 10 are set to be the same, so that the material of the first contact and the connection of the conductive bus are the same, so as to ensure the current carrying performance of the first contact and the conductive bus.

[0038] In some embodiments, please refer to Figure 1 and Figure 2 , Figure 1 This is a structural cross-sectional view of an embodiment of a high-voltage box using a high-breaking-capacity laser welding process, where external terminals 10 and tellurium terminals 20 are connected by filler wire welding via a first connecting platform 11 and a connecting groove 22. Figure 2 for Figure 1 A cross-sectional view of the external connection terminal 10 shows that the external connection terminal 10 also includes a second connection platform 12. Along the first direction X, the second connection platform 12 is located on the side of the external connection terminal 10 away from the tellurium copper terminal 20. Along the first direction X, the second connection platform 12 has a minimum length a mm, satisfying: 2≤a≤5, to meet the requirements of the busbar connection.

[0039] In some embodiments, 'a' is preferably any value from 2, 2.5, 3, 3.5, 4, 4.5, 5 or any two values ​​to accommodate conductive busbars of different thicknesses.

[0040] In some embodiments, please refer to Figure 1 , Figure 2 and Figure 3 , Figure 1 This is a structural cross-sectional view of an embodiment of a high-voltage box using a high-breaking-capacity laser welding process, where external terminals 10 and tellurium terminals 20 are connected by filler wire welding via a first connecting platform 11 and a connecting groove 22. Figure 2 for Figure 1 Cross-sectional view of the external connector 10. Figure 3 for Figure 1A cross-sectional view of the tellurium copper terminal 20 is shown in this application. The tellurium copper terminal 20 has a connecting groove 22 extending along a first direction X, with the opening of the connecting groove 22 facing the external terminal 10. The external terminal 10 includes a first connecting platform 11, which is disposed along the first direction X on the side of the external terminal 10 near the tellurium copper terminal 20. The first connecting platform 11 is at least partially disposed in the connecting groove 22 to connect the external terminal 10 and the tellurium copper terminal 20. Specifically, the outer wall of the first connecting platform 11 and the inner wall of the connecting groove 22 are connected by a filler wire bonding process to achieve the connection between the external terminal 10 and the tellurium copper terminal 20. Alternatively, please refer to... Figure 4 , Figure 5 and Figure 6 , Figure 4 This is a front view of an embodiment of a high-voltage box with high breaking capacity laser welding process provided in this application, in which the external terminal 10 and tellurium copper terminal 20 are brazed together using a first connecting surface 13 and a second connecting surface 23. Figure 5 for Figure 4 Front view of the middle and external connector 10 Figure 6 for Figure 4 The front view of the tellurium copper terminal 20 shows that, along the first direction X, the external terminal 10 has a first connecting surface 13 on the side away from the second connecting platform 12, and the tellurium copper terminal 20 has a second connecting surface 23 on the side closer to the external terminal 10. The first connecting surface 13 and the second connecting surface 23 are connected by brazing to achieve the connection between the external terminal 10 and the tellurium copper terminal 20. Understandably, this application designs the first contact in two parts. The external terminal 10 can be designed according to the material of the external conductive bus to ensure the electrical connection performance between the first contact and the external conductive bus. The tellurium copper terminal 20 is made of tellurium copper and connected to the second contact. Tellurium copper has higher corrosion resistance and strength than pure copper, which can effectively improve the high current breaking capacity between the contacts.

[0041] In some embodiments, please refer to Figure 4 and Figure 6 , Figure 4 This is a front view of an embodiment of a high-voltage box with high breaking capacity laser welding process provided in this application, in which the external terminal 10 and tellurium copper terminal 20 are brazed together using a first connecting surface 13 and a second connecting surface 23. Figure 6 for Figure 4 The front view of the tellurium copper terminal 20 shows that, along the first direction X, the tellurium copper terminal 20 has a minimum length b mm, satisfying: 5 ≤ b, to ensure the breaking performance of the stationary and moving contacts.

[0042] In some embodiments, b can be any value from 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10 or any value between any two values.

[0043] In some embodiments, the electrical control device may be a circuit breaker, relay, contactor, switchgear, overload protector, precharge module or capacitor, etc., wherein the first contact is a stationary contact and the second contact is a moving contact. To further improve the breaking performance between the stationary contact and the moving contact, the material of the second contact is tellurium copper.

[0044] Understandably, the high-voltage box for laser welding process with high breaking capacity provided in the embodiments of this application includes a housing, a conductive bus, and an electrical control device; the conductive bus is disposed in the housing and has a connection hole; the electrical control device is disposed in the housing and includes a first contact and a second contact, the first contact including an external terminal 10 and a tellurium copper terminal 20, the external terminal 10 and the tellurium copper terminal 20 being connected; the external terminal 10 is at least partially disposed in the connection hole and laser welded to the conductive bus to realize the electrical connection of the electrical control device with other electrical components; the tellurium copper terminal 20 is connected to the second contact. This application divides the first contact into two parts: an external terminal 10 and a tellurium copper terminal 20. The external terminal 10 is used to connect to the outside, and the tellurium copper terminal 20 is used to connect to the second contact. The external terminal 10 can be designed according to the material of the external conductive bus to ensure the electrical connection performance between the stationary contact and the external conductive bus. The tellurium copper terminal 20 is made of tellurium copper and is connected to the second contact. Tellurium copper has higher corrosion resistance and strength than pure copper, which can improve the high current breaking capacity between the contacts.

[0045] For example, in a 250A high-voltage box sample, when a high-voltage relay is designed using a pure copper stationary contact and a tellurium copper moving contact, the breaking current between the pure copper stationary contact and the tellurium copper moving contact can only reach 1500A-2000A. However, when using the design provided in this application, the breaking current between the stationary contact and the moving contact can reach 3000A-3500A, significantly improving its breaking capacity.

[0046] This application has provided a detailed description of a high-voltage box with high breaking capacity laser welding process provided in the embodiments of this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A high-voltage box for laser welding process with high breaking capacity, characterized in that, include: case; A conductive busbar is disposed in the housing and has connection holes; An electronic control device is disposed in the housing. The electronic control device includes a first contact and a second contact. The first contact includes an external terminal and a tellurium copper terminal. The external terminal (10) is at least partially disposed in the connection hole and laser welded to the conductive bus. The tellurium copper terminal (20) is connected to the second contact.

2. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The tellurium copper terminal (20) has a connecting groove (22) with the opening of the connecting groove (22) facing the external terminal (10); The external terminal (10) includes a first connecting platform (11), which is disposed on the side of the external terminal (10) near the tellurium copper terminal (20). The first connecting platform (11) is at least partially disposed in the connecting groove (22) to connect the external terminal (10) and the tellurium copper terminal (20).

3. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, Along the arrangement direction of the tellurium copper terminal (20) and the external terminal (10), the tellurium copper terminal (20) has a minimum length b mm, satisfying: 5 ≤ b.

4. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The external terminal (10) further includes a second connecting platform (12), which is disposed on the side of the external terminal (10) away from the tellurium copper terminal (20); Along the arrangement direction of the tellurium copper terminal (20) and the external connection terminal (10), the second connection platform (12) has a minimum length a mm, satisfying: 2≤a≤5.

5. The high-voltage box for laser welding process with high breaking capacity according to claim 4, characterized in that, It satisfies: a=2.5, a=3, or a=4.

6. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The external terminal (10) and the tellurium copper terminal (20) are brazed together.

7. The high-voltage box for laser welding process with high breaking capacity according to claim 2, characterized in that, The first connecting platform (11) and the connecting groove (22) are connected by filler wire welding.

8. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The external terminal (10) is a pure copper terminal or a pure aluminum terminal.

9. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The conductive busbar is a pure copper conductive busbar or a pure aluminum conductive busbar.

10. The high-voltage box for laser welding process with high breaking capacity according to claim 1, characterized in that, The electrical control device is a circuit breaker, relay, contactor, switchgear, overload protector, precharge module or capacitor, the first contact is a stationary contact and the second contact is a moving contact.

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