Aluminum row wire harness structure and vehicle

Abstract

The utility model relates to the technical field of wire harnesses, in particular to an aluminum row wire harness structure and a vehicle, the aluminum row wire harness structure comprises at least one terminal, at least one aluminum wire and at least one aluminum row which are connected together, the terminal and the aluminum wire, the aluminum wire and the aluminum row, and the aluminum wires are connected in a welding mode; the overlapping rates of the welding parts between the aluminum wires and the terminals, between the aluminum wires and the aluminum row and between the aluminum wires are all larger than or equal to 90%. According to the utility model, the temperature rise of the contact position is reduced, and the problem that the aluminum is easy to creep at high temperature is effectively relieved.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, specifically to an aluminum busbar wire harness structure and a vehicle. Background Technology

[0002] With the rapid development of electric vehicle technology, their functional configurations have become much richer compared to traditional cars. For example, 4C / 5C fast charging technology, large-size displays, in-car refrigerators, zero-gravity seats, and high-power electrical equipment such as external power discharge devices have become mainstream configurations in many mid-to-high-end electric vehicles. These added functions and devices not only improve the comfort and convenience of electric vehicles, but also pose new challenges to their electrical systems.

[0003] In the electrical system of electric vehicles, low-voltage and high-voltage wiring are two crucial components. For the low-voltage wiring, the battery needs to power all the low-voltage electrical components in the vehicle. To meet this requirement, large-diameter, long wires are typically used in the overall vehicle wiring layout. However, these wires often encounter space constraints during installation. Especially when the wire diameter is too large, it can lead to installation difficulties within limited space. For example, when wiring from the trunk along the sill to the front compartment, the limited height space at the sill often results in installation difficulties due to excessively large wire diameters.

[0004] In high-voltage wiring harnesses, the introduction of 4C / 5C fast charging technology and the increase in motor horsepower necessitate the use of larger diameter charging and drive cables for electric vehicles. These large-diameter charging cables are typically routed along the rear wheel hub, but the large wire diameter presents challenges in their placement. This not only increases the difficulty of electric vehicle production but also raises production costs.

[0005] To address these issues, researchers have begun exploring the use of flattened structures and alternative materials to reduce the space occupied by wire harnesses, lower costs, and achieve lightweighting. Among these, aluminum busbar harnesses have received widespread attention as a potential alternative. However, aluminum busbar harnesses still face some technical challenges in practical applications.

[0006] First, aluminum is prone to creep at high temperatures, which affects its mechanical and electrical properties. Second, aluminum is easily oxidized, forming an aluminum oxide film on its surface, which impacts the conductivity and connection reliability of the wires. Furthermore, there is an electrochemical corrosion problem between aluminum and copper; when aluminum and copper come into contact, a galvanic cell forms at the contact point, accelerating aluminum corrosion. Finally, the connection technology for aluminum wires is also challenging, especially the connection methods between aluminum wires and between aluminum wires and copper terminals, which need to ensure the reliability and durability of the connections.

[0007] Although some patents have proposed using aluminum busbars and aluminum wires to replace power harnesses, these patents mainly focus on the connection methods between aluminum busbars and aluminum wires or between aluminum busbars and terminals, and have not fully solved the difficult problems such as aluminum wire connection, aluminum product oxidation, high-temperature creep, and electrochemical corrosion between copper and aluminum.

[0008] Therefore, it is necessary to develop a new aluminum busbar harness structure and vehicle. Summary of the Invention

[0009] The purpose of this invention is to provide an aluminum busbar harness structure and vehicle that can effectively alleviate the problem of aluminum creeping at high temperatures.

[0010] In a first aspect, the aluminum busbar harness structure of this utility model includes at least one terminal, at least one aluminum wire and at least one aluminum busbar connected together, wherein the terminal and the aluminum wire, the aluminum wire and the aluminum busbar, and the aluminum wire and the aluminum wire are all connected by welding; the overlap rate of the welding parts between the aluminum wire and the terminal, between the aluminum wire and the aluminum busbar, and between the aluminum wire and the aluminum wire is greater than or equal to 90%.

[0011] Optionally, the welding area of ​​the aluminum busbar is provided with multiple piercing structures. The piercing structures can break the oxide layer on the surface of the aluminum conductor during the welding process and increase the mechanical interlocking force between the welding material and the aluminum conductor.

[0012] Optionally, the welded areas of the aluminum conductors, terminals, and aluminum busbars are all provided with a zinc plating layer or a tin plating layer. The zinc plating layer or tin plating layer can prevent the "galvanic cell" reaction formed between copper and aluminum, thereby avoiding corrosion of the welded areas.

[0013] Optionally, a sealing grease layer and heat shrink tubing are provided at the welding points between the aluminum conductor and the terminal, the aluminum conductor and the aluminum busbar, and the aluminum conductors themselves, with the heat shrink tubing located outside the sealing grease layer. The sealing grease layer eliminates the possibility of air entering the connection point, preventing electrochemical corrosion. The heat shrink tubing provides additional sealing protection, ensuring that the welding points are not affected by the external environment. This double-sealing design improves the corrosion resistance and reliability of the aluminum busbar harness.

[0014] Optionally, the aluminum busbars are connected to each other using aluminum busbar connectors. Aluminum busbar connectors can easily connect multiple aluminum busbars together to form a larger circuit network. This connection method simplifies the installation and maintenance process of the aluminum busbar harness and improves work efficiency.

[0015] Optionally, the terminals are connected to the aluminum conductors, the aluminum conductors to the aluminum busbars, and the aluminum conductors to each other using ultrasonic welding. Ultrasonic welding offers advantages such as high efficiency, speed, and zero pollution, ensuring a good weld connection between the terminals, aluminum conductors, and aluminum busbars. This welding method improves the production efficiency and quality of the aluminum busbar harness.

[0016] Optionally, the terminals can be made of copper or aluminum. The appropriate material can be selected to meet different application scenarios. Copper terminals offer good conductivity and corrosion resistance, while aluminum terminals are lighter and more cost-effective. This choice provides flexibility to meet diverse design requirements.

[0017] Optionally, the aluminum wire is provided with a wire harness fixing clip for fixing the aluminum wire to the vehicle body. This effectively prevents the aluminum wire from loosening or falling off during vehicle operation.

[0018] Optionally, the aluminum strip is provided with an aluminum strip fixing clip for fixing the aluminum strip to the vehicle body. This effectively prevents the aluminum strip from loosening or falling off during vehicle operation.

[0019] Secondly, the vehicle described in this utility model adopts the aluminum busbar harness structure described in this utility model.

[0020] The beneficial effects of this invention are as follows: The overlap rate of the welded parts in this invention reaches at least 90%, which means that the contact area of ​​the welded joint is large, the resistance when current passes through is small, and therefore less heat is generated. This helps to reduce the temperature rise at the contact point and effectively alleviates the problem of aluminum creep (i.e., slow plastic deformation of the material under long-term stress) at high temperatures. Creep reduces the conductivity and mechanical properties of the wire, while the high overlap rate of the weld can effectively suppress this adverse phenomenon. In addition, this invention tightly connects the terminals, aluminum wires, and aluminum busbars together through welding to form a stable aluminum busbar harness structure. This connection method improves the reliability and durability of the harness. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the aluminum busbar harness structure described in the embodiments of this application;

[0022] Figure 2 for Figure 1 Enlarged schematic diagram of part A (i.e., the connection between the aluminum conductor and the aluminum busbar).

[0023] Figure 3 for Figure 1 Enlarged schematic diagram of part B (i.e., the connection between aluminum busbars).

[0024] Figure 4 for Figure 1 Enlarged schematic diagram of section C (i.e., the connection between aluminum wires);

[0025] Figure 5 for Figure 1 Enlarged schematic diagram of part D (i.e., the connection between the aluminum busbar and the terminal);

[0026] Figure 6 This is a schematic diagram of the terminal structure in an embodiment of this application;

[0027] Figure 7 This is a schematic diagram of the nickel sheets assembled by riveting in an embodiment of this application;

[0028] Figure 8 This is a schematic diagram of the puncture structure in an embodiment of this application;

[0029] Figure 9 This is a schematic diagram of the zinc plating layer in an embodiment of this application;

[0030] Figure 10 This is a schematic diagram of the tin plating layer in an embodiment of this application;

[0031] In the diagram: 1-Terminal, 11-First Terminal, 12-Second Terminal, 13-Third Terminal, 2-Aluminum Wire, 21-First Aluminum Wire, 22-Second Aluminum Wire, 23-Third Aluminum Wire, 24-Fourth Aluminum Wire, 3-Wire Harness Fixing Clip, 4-Aluminum Busbar Fixing Clip, 5-Aluminum Busbar, 51-First Aluminum Busbar, 52-Second Aluminum Busbar, 53-Third Aluminum Busbar, 6-Aluminum Busbar Connector, 7-Nickel Sheet, 8-Sealing Grease Layer, 9-Heat Shrink Tubing, a-Piercing Structure, b-Zinc Plating Layer, c-Tin Plating Layer Detailed Implementation

[0032] The embodiments of this utility model will be described below with reference to the accompanying drawings and preferred embodiments. Those skilled in the art can understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be understood that the preferred embodiments are only for illustrating this utility model and not for limiting the scope of protection of this utility model.

[0033] like Figure 1 As shown in the embodiment of this application, an aluminum busbar harness structure includes at least one terminal 1, at least one aluminum wire 2 and at least one aluminum busbar 5 connected together, wherein the terminal 1 and the aluminum wire 2, the aluminum wire 2 and the aluminum busbar 5, and the aluminum wire 2 and the aluminum wire 5 are all connected by welding.

[0034] Due to the special properties of aluminum products, such as high-temperature creep, easy oxidation, and electrochemical corrosion, the following controls are required:

[0035] 1. High-temperature creep control: When welding aluminum wire 2 to terminal 1, aluminum wire 2 to aluminum busbar 5, and aluminum wire 2 to aluminum wire 2, the contact area between the two should be increased to ensure that the overlap rate of the welded parts is at least 90% (overlap rate usually refers to the degree of overlap between two workpieces to be welded at the joint). See [link to relevant documentation]. Figure 2 This means that the contact area at the weld is large, the resistance is low when current flows, and therefore less heat is generated. This helps reduce the temperature rise at the contact point and effectively alleviates the problem of aluminum creeping at high temperatures (i.e., slow plastic deformation of the material under prolonged stress). Creep reduces the conductivity and mechanical properties of wires, while high overlap welding effectively suppresses this adverse phenomenon.

[0036] 2. Oxidation Control: Before welding aluminum conductor 2 to terminal 1, aluminum conductor 2 to aluminum busbar 5, and aluminum conductor 2 to aluminum conductor 2, in order to effectively control oxidation and improve welding quality, multiple puncture structures a need to be provided on the welding parts of aluminum busbar 5 (see...). Figure 8 By puncturing structure a, the oxide layer on the surface of the aluminum conductor 2 can be damaged during the welding process, increasing the mechanical bonding force between the welding material and the aluminum conductor. To ensure the sealing performance after welding, double-arm heat shrink tubing can be used to seal the welded area, and the sealing rating of the double-arm heat shrink tubing must meet or exceed the IP67 standard. To further reduce the risk of oxidation, the oxide layer, oil, and other impurities on the surface of the aluminum busbar 5 can be removed. At the same time, a CCD imager or high-magnification magnifying glass can be used to observe whether there are cracks or penetrating scratches at the ends to prevent the formation of an oxide layer at the ends.

[0037] 3. Electrochemical corrosion: This mainly targets the "galvanic cell" reaction formed at the contact between copper and aluminum, causing corrosion at the welded areas. There are two main methods:

[0038] Firstly, a galvanized layer b is provided at the welding points of aluminum conductor 2, terminal 1, and aluminum busbar 5 (see...). Figure 9 ) or tin plating c (see Figure 10 This ensures that the elements in contact between the two are consistent.

[0039] Secondly, a sealing grease layer 8 should be added to the welded area to prevent air from entering the connection. Heat shrink tubing 9 should also be used for sealing, with the heat shrink tubing 9 placed outside the sealing grease layer 8 (see [link]). Figure 4 ).

[0040] In one possible embodiment, terminal 1 is a 90-degree copper terminal or a 90-degree aluminum terminal. Suitable materials can be selected to meet different application scenarios as needed. Copper terminals offer good conductivity and corrosion resistance, while aluminum terminals are lighter and more cost-effective. This choice provides flexibility to meet diverse design requirements.

[0041] like Figure 3 As shown, in one possible embodiment, aluminum busbars 5 are connected to each other using aluminum busbar connectors 6. The aluminum busbar connectors 6 can easily connect multiple aluminum busbars 5 together to form a larger circuit network. This connection method simplifies the installation and maintenance process of the aluminum busbar harness structure and improves work efficiency.

[0042] In one possible embodiment, the terminals 1 and aluminum wire 2, the aluminum wire 2 and aluminum busbar 5, and the aluminum wire 2 and aluminum wire 2 are all connected by ultrasonic welding. Ultrasonic welding has the advantages of high efficiency, speed and no pollution, and can ensure that a good welded connection is formed between the two. This welding method improves the production efficiency and quality of aluminum busbar harnesses.

[0043] In one possible embodiment, a wire harness fixing clip 3 is provided on the aluminum wire 2; this clip is used to securely install the aluminum wire 2 onto the vehicle body, effectively preventing the aluminum wire 2 from loosening or falling off during vehicle operation.

[0044] In one possible embodiment, the aluminum strip 5 is provided with an aluminum strip fixing clip 4 for fixing the aluminum strip 5 to the vehicle body, which can effectively prevent the aluminum strip 5 from loosening or falling off during vehicle operation.

[0045] like Figures 1 to 7 As shown, in one example, an aluminum busbar harness structure includes three terminals 1, four aluminum wires 2, three aluminum busbars 5, an aluminum busbar connector 6, and a nickel strip 7. The three terminals 1 are designated as first terminal 11, second terminal 12, and third terminal 13. The four aluminum wires 2 are designated as first aluminum wire 21, second aluminum wire 22, third aluminum wire 23, and fourth aluminum wire 24. The three aluminum busbars 5 are designated as first aluminum busbar 51, second aluminum busbar 52, and third aluminum busbar 53. The specific connection relationships are as follows:

[0046] The first terminal 11, the first aluminum wire 21, the first aluminum busbar 51, the second aluminum wire 22, the third aluminum busbar 53, the third aluminum wire 23, the fourth aluminum wire 24, and the second terminal 12 are connected sequentially. The first terminal 11 and the first aluminum wire 21 are connected by ultrasonic welding. The connections between the first aluminum wire 21 and the first aluminum busbar 51, between the first aluminum busbar 51 and the second aluminum wire 22, between the second aluminum wire 22 and the third aluminum busbar 53, between the third aluminum busbar 53 and the third aluminum wire 23, between the third aluminum wire 23 and the fourth aluminum wire 24, and between the fourth aluminum wire 24 and the second terminal 12 are all made by ultrasonic welding. The third terminal 13 and the third aluminum wire 23 are connected by ultrasonic welding. The aluminum busbar connector 6 connects the third aluminum busbar 53 and the second aluminum busbar 52 together using quick-connect springs. The nickel sheet 7 is connected to the second aluminum busbar 52 by riveting.

[0047] In this embodiment of the application, a vehicle adopts the aluminum busbar harness structure as described in this embodiment of the application.

[0048] The above embodiments are preferred embodiments of the present utility model, but the embodiments of the present utility model are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present utility model shall be considered equivalent substitutions and shall be included within the protection scope of the present utility model.

Claims

1. An aluminum busbar harness structure, comprising at least one terminal (1), at least one aluminum conductor (2), and at least one aluminum busbar (5) connected together, wherein, The terminals (1) and aluminum wires (2), aluminum wires (2) and aluminum bars (5), and aluminum wires (2) and aluminum wires (2) are all connected by welding. The feature is that the overlap rate of the welding parts between the aluminum wires (2) and terminals (1), between the aluminum wires (2) and aluminum bars (5), and between the aluminum wires (2) and aluminum wires (2) is greater than or equal to 90%.

2. The aluminum busbar harness structure according to claim 1, characterized in that, The aluminum busbar (5) has multiple puncture structures (a) on its welding parts.

3. The aluminum busbar harness structure according to claim 1, characterized in that, The aluminum conductor (2), terminal (1) and aluminum busbar (5) are all provided with a zinc plating layer (b) or a tin plating layer (c) at the welding parts.

4. The aluminum busbar harness structure according to claim 1, characterized in that, A sealing grease layer (8) and a heat shrink tube (9) are provided at the welding points between the aluminum wire (2) and the terminal (1), between the aluminum wire (2) and the aluminum busbar (5), and between the aluminum wire (2) and the aluminum wire (2), and the heat shrink tube (9) is located outside the sealing grease layer (8).

5. The aluminum busbar harness structure according to claim 4, characterized in that: The aluminum busbars (5) are connected to each other by an aluminum busbar connector (6).

6. The aluminum busbar harness structure according to claim 1, characterized in that: The terminals (1) and aluminum wires (2), aluminum wires (2) and aluminum busbars (5), and aluminum wires (2) and aluminum wires (2) are all connected by ultrasonic welding.

7. The aluminum busbar harness structure according to claim 1, characterized in that: The terminal (1) is made of copper or aluminum.

8. The aluminum busbar harness structure according to claim 1, characterized in that: The aluminum wire (2) is provided with a wire harness fixing clip (3); used to fix the aluminum wire (2) to the vehicle body.

9. The aluminum busbar harness structure according to claim 1, characterized in that: The aluminum strip (5) is provided with an aluminum strip fixing clip (4) for fixing the aluminum strip (5) to the vehicle body.

10. A vehicle, characterized in that: The aluminum busbar harness structure is adopted as described in any one of claims 1 to 9.

Images