Aluminum bar electric connection structure of new energy automobile
By combining injection-molded mounting brackets, mounting nuts, and bolts, the problem of unstable aluminum busbar connections was solved, achieving tight connection of the aluminum busbars and stable current transmission, thus reducing the weight and maintenance costs of new energy vehicles.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-08
- Publication Date
- 2026-03-06
AI Technical Summary
In new energy vehicles, copper busbars are heavy and costly, while aluminum busbars have low compressive strength, high contact resistance, are prone to corrosion, and have unstable connections, resulting in unstable current and poor safety.
The design employs a combination of injection-molded mounting brackets, mounting nuts, and bolts. Through limiting surfaces, supporting surfaces, and threaded connections, it ensures continuous limiting force on the aluminum busbar in the axial direction. Combined with the coating design, it improves conductivity and corrosion resistance.
It achieves a tight connection between aluminum busbars, enhances structural stability and electrical conductivity, ensures stable current transmission, reduces weight and cost, adapts to diverse design needs, and facilitates maintenance.
Smart Images
Figure CN223978162U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of new energy electric vehicle technology, and in particular to an aluminum busbar connection structure for new energy vehicles. Background Technology
[0002] In the electrical connections of new energy vehicles, copper busbars provide electrical connections for electrical units. Traditional copper busbars in new energy vehicles are heavy. With the increasing popularity of new energy vehicles and the widespread use of copper, the price of copper is constantly rising, and its share of the cost in new energy vehicle electrical connections is also increasing. Therefore, there is an urgent need for new materials and new structural designs to reduce costs and weight. While aluminum busbars can reduce the weight of the power distribution assembly, they have low compressive strength, high contact resistance, poor conductivity, and are prone to electrochemical corrosion. Under the clamping force of bolts, the aluminum busbar's conductivity may be disrupted. Thermal expansion and contraction of the material can lead to plastic deformation over time, causing bolt torque attenuation and loosening of the aluminum busbar. Summary of the Invention
[0003] This application provides an aluminum busbar electrical connection structure for new energy vehicles, which achieves a tight connection between aluminum busbars through a combination design of injection-molded mounting brackets, mounting nuts, and bolts.
[0004] To achieve the above objectives, this utility model provides the following technical solution: an aluminum busbar electrical connection structure for new energy vehicles, comprising:
[0005] Injection-molded mounting brackets are installed at the connection of several aluminum strips stacked together. The injection-molded mounting brackets include mounting grooves with the same orientation as the aluminum strips for mounting the aluminum strips, limiting grooves at the lower end of the mounting grooves, and mounting holes connecting the mounting grooves and the limiting grooves. The diameter of the mounting holes is larger than the diameter of the limiting grooves.
[0006] The mounting nut is integrally injection molded with the injection molded mounting bracket. The mounting nut includes, in sequence downwards, a support portion at least partially embedded in the mounting hole and a mounting portion embedded in the limiting groove. The upper end of the support portion includes a support surface for supporting the lower end of the aluminum busbar.
[0007] The bolt includes, in sequence downwards, a limiting part and a threaded part, and the lower end of the limiting part includes a limiting surface for limiting the upper end of the aluminum busbar;
[0008] The threaded part passes through several aluminum bars in sequence, so that the limiting surface and the supporting surface work together to continuously apply a limiting force in the axial direction to the several aluminum bars. The lower end of the threaded part is embedded in the interior of the mounting part and is threadedly connected to the mounting part.
[0009] Compared with the prior art, the advantages of this utility model are:
[0010] Through the combined design of injection-molded mounting brackets, mounting nuts, and bolts, a tight connection between aluminum busbars is achieved. The injection-molded mounting brackets provide a stable mounting base for the aluminum busbars, while the cooperation of the mounting nuts and bolts ensures that the aluminum busbars receive continuous limiting force in the axial direction. The integral injection-molded connection of the injection-molded mounting brackets and mounting nuts, as well as the tight cooperation between the bolts and the aluminum busbars, together constitute a high-strength connection structure, thereby enhancing the stability of the entire structure. At the same time, since the mounting nuts are equipped with support parts, the support area is increased, preventing the aluminum busbars from loosening due to bolt torque attenuation, ensuring good electrical conductivity, thereby ensuring stable current transmission, improving energy utilization efficiency, and also improving the overall safety of new energy vehicles.
[0011] Meanwhile, the structure can adapt to the connection requirements of aluminum busbars of different quantities and thicknesses. By simply adjusting the length of the bolts and the specifications of the mounting nuts, it can meet different application scenarios, making the structure widely applicable in the diversified design of new energy vehicles. At the same time, when maintenance or replacement of aluminum busbars is required, the aluminum busbars can be easily disassembled by simply loosening the bolts, without the need for large-scale disassembly of the entire structure, thus reducing maintenance costs and time costs.
[0012] As an improvement, the outer peripheral wall of the mounting part is provided with several stop parts at intervals along the axial direction. Several racks are provided with protruding circumferentially on the outer peripheral wall of the stop parts. The side wall of the limiting groove is recessed outward along the circumferential direction to provide rack grooves corresponding to the stop parts. The racks are embedded in the rack grooves. The precise fitting design of the racks and rack grooves ensures a stable connection between the mounting nut and the injection-molded mounting bracket, effectively preventing loosening or falling off due to vibration or impact. At the same time, it enables the mounting nut to resist deformation more effectively when subjected to torsional force, thereby improving the stability of the entire electrical connection structure.
[0013] As an improvement, the bottom surface of the mounting groove is provided with a first positioning post and a second positioning post extending upward on both sides of the mounting hole corresponding to the aluminum strip. The first positioning post and the second positioning post provide precise reference points for the installation of the aluminum strip, ensuring that the aluminum strip can be accurately aligned and installed on the injection-molded mounting bracket.
[0014] As an improvement, the aluminum strip at the lower end is provided with a first positioning through hole corresponding to the first positioning post. The upper end of the first positioning post is embedded in the first positioning through hole. The cooperation between the first positioning post and the first positioning through hole enables the precise positioning of the aluminum strip. Since the shape and size of the positioning post match the through hole, the aluminum strip can quickly and accurately find its correct position during installation, avoiding misalignment or deviation during the installation process. At the same time, it provides additional fixing force and enhances the connection stability between the aluminum strip and the injection molded mounting bracket.
[0015] As an improvement, the aluminum strip at the upper end is provided with a second positioning through hole corresponding to the second positioning post. The upper end of the second positioning post is embedded in the second positioning through hole. The cooperation between the second positioning post and the second positioning through hole enables the precise positioning of the aluminum strip. Since the shape and size of the positioning post match the through hole, the aluminum strip can quickly and accurately find its correct position during installation, avoiding misalignment or deviation during the installation process. At the same time, it provides additional fixing force and enhances the connection stability between the aluminum strip and the injection molded mounting bracket.
[0016] As an improvement, the bolt also includes an elastic part and a bolt head. The elastic part is disposed between the bolt head and the limiting part, such that the upper end of the elastic part abuts against the bolt head, and the lower end of the elastic part abuts against the upper end of the limiting part, so that the limiting surface is pressed tightly against the upper end surface of the aluminum busbar. The elastic part is disposed between the bolt head and the limiting part, such that the upper end of the elastic part abuts against the bolt head, and the lower end abuts against the upper end of the limiting part, so that the limiting surface can more effectively press against the upper end surface of the aluminum busbar, ensuring the tightness of the connection. The elastic part has a certain elastic deformation capacity, which can adapt to the slight deformation of the aluminum busbar caused by factors such as temperature changes and mechanical stress, thereby maintaining the stability of the connection.
[0017] As an improvement, there is a height difference between the second positioning post and the first positioning post. In the case of multi-layer aluminum busbar connection, the height difference allows each layer of aluminum busbar to overlap with other layers at the optimal angle and position, reducing friction and resistance during installation and making the connection smoother.
[0018] As an improvement, the aluminum busbar includes an aluminum busbar body and a coating. The coating consists of a nickel layer and a tin layer. The nickel layer has a thickness of 2μm-6μm, and the tin layer has a thickness of 3μm-8μm. This reduces contact resistance, provides conductivity, and improves the corrosion resistance of the aluminum busbar.
[0019] As an improvement, the body of the aluminum busbar is made of aluminum, including but not limited to Al6101 and Al1060. Replacing the copper busbar with an aluminum busbar reduces weight and lowers costs. Attached Figure Description
[0020] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:
[0021] Figure 1 An exploded view of an aluminum busbar electrical connection structure for a new energy vehicle;
[0022] Figure 2 This is a schematic diagram of an aluminum busbar electrical connection structure for a new energy vehicle.
[0023] Figure 3 This is a cross-sectional view of an aluminum busbar electrical connection structure for a new energy vehicle.
[0024] The markings in the above figures are as follows: 1. Injection-molded mounting bracket; 1.1. Mounting groove; 1.2. First positioning post; 1.3. Second positioning post; 1.4. Limiting groove; 1.5. Rack groove; 1.6. Mounting hole; 2. Mounting nut; 2.1. Support part; 2.2. Mounting part; 2.3. Stopping part; 3. Bolt; 3.1. Limiting part; 3.2. Threaded part; 3.3. Elastic part; 3.4. Bolt head; 4. Aluminum busbar; 4.1. First positioning through hole; 4.2. Second positioning through hole. Detailed Implementation
[0025] In this utility model, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "planar direction", "circumferential", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0026] like Figures 1 to 3 As shown, an aluminum busbar electrical connection structure for a new energy vehicle includes an injection-molded mounting bracket 1, mounting nuts 2, and bolts 3. The injection-molded mounting bracket 1 is disposed at the connection point of several stacked aluminum busbars 4. The injection-molded mounting bracket 1 includes a mounting groove 1.1 with the same orientation as the aluminum busbars 4 for mounting the aluminum busbars 4, a limiting groove 1.4 disposed at the lower end of the mounting groove 1.1, and a mounting hole 1.6 connecting the mounting groove 1.1 and the limiting groove 1.4. The diameter of the mounting hole 1.6 is larger than the diameter of the limiting groove 1.4. The mounting nuts 2 are integrally injection-molded with the injection-molded mounting bracket 1, and the mounting nuts 2 are sequentially downwardly embedded, at least partially, within the mounting hole 1.6. The support part 2.1 and the mounting part 2.2 embedded in the limiting groove 1.4 are provided. The upper end of the support part 2.1 includes a support surface for supporting the lower end of the aluminum busbar 4. The bolt 3 includes a limiting part 3.1 and a threaded part 3.2 in sequence downwards. The lower end of the limiting part 3.1 includes a limiting surface for limiting the upper end of the aluminum busbar 4. The threaded part 3.2 passes through several aluminum busbars 4 in sequence, so that the limiting surface and the support surface cooperate to make the limiting part 3.1 and the support part 2.1 continuously apply a limiting force in the axial direction to several aluminum busbars 4. The lower end of the threaded part 3.2 is embedded in the mounting part 2.2 and is threadedly connected to the mounting part 2.2.
[0027] The outer peripheral wall of the mounting part 2.2 is provided with a number of stop parts 2.3 at intervals along the axial direction. The outer peripheral wall of the stop part 2.3 is provided with a number of racks protruding in the circumferential direction. The side wall of the limiting groove 1.4 is recessed outward in the circumferential direction to provide a rack groove 1.5 corresponding to the stop part 2.3. The rack is embedded in the inside of the rack groove 1.5.
[0028] The bottom surface of the mounting groove 1.1 is provided with a first positioning post 1.2 and a second positioning post 1.3 extending upwards on both sides of the mounting hole 1.6, corresponding to the aluminum strip 4.
[0029] The aluminum strip 4 at the lower end is provided with a first positioning through hole 4.1 corresponding to the first positioning post 1.2, and the upper end of the first positioning post 1.2 is embedded in the first positioning through hole 4.1.
[0030] The aluminum strip 4 at the upper end is provided with a second positioning through hole 4.2 corresponding to the second positioning post 1.3, and the upper end of the second positioning post 1.3 is embedded in the second positioning through hole 4.2.
[0031] Bolt 3 also includes an elastic part 3.3 and a bolt head 3.4. The elastic part 3.3 is disposed between the bolt head 3.4 and the limiting part 3.1, such that the upper end of the elastic part 3.3 abuts against the bolt head 3.4, and the lower end of the elastic part 3.3 abuts against the upper end of the limiting part 3.1 so that the limiting surface abuts against the upper end surface of the aluminum strip 4.
[0032] There is a height difference between the second positioning post 1.3 and the first positioning post 1.2.
[0033] The aluminum busbar 4 includes an aluminum busbar body and a plating layer, which includes a nickel layer and a tin layer in sequence. The thickness of the nickel layer is 2μm-6μm and the thickness of the tin layer is 3μm-8μm.
[0034] The aluminum busbar body is made of aluminum, including but not limited to Al6101 and Al1060.
[0035] When the injection molding mounting bracket 1 is injection molded, the mounting part 2.2 is embedded in the inside of the limiting groove 1.4, while the rack of the stopping part 2.3 is embedded in the inside of the rack groove 1.5, and the lower end of the support part 2.1 is embedded in the inside of the mounting hole 1.6;
[0036] When aluminum strips 4 are stacked, one side of aluminum strip 4 is placed into the mounting groove 1.1, so that the upper end of the first positioning post 1.2 is embedded in the first positioning through hole 4.1. Then, the other side of aluminum strip 4 is placed into the mounting groove 1.1 and overlapped with the upper end of the aluminum strip 4 on one side, so that the upper end of the second positioning post 1.3 is embedded in the second positioning through hole 4.2.
[0037] When installing bolt 3, the threaded part 3.2 passes through several aluminum strips 4 in sequence, so that the upper end of the elastic part 3.3 abuts against the bolt head 3.4, and the lower end of the elastic part 3.3 abuts against the upper end of the limiting part 3.1 so that the limiting surface abuts against the upper end surface of the aluminum strip 4. The supporting surface of the supporting part 2.1 abuts against the aluminum strip at the lower end, and the aluminum strip 4 at the upper end abuts against the aluminum strip 4 at the lower end, so that the limiting part 3.1 and the supporting part 2.1 continuously apply a limiting force in the axial direction to the two aluminum strips 4. The lower end of the threaded part 3.2 is embedded in the interior of the mounting part 2.2 and is threadedly connected to the mounting part 2.2.
[0038] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the technical solution of the present invention, or the direct application of the concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.
Claims
1. An aluminum power distribution connection structure for a new energy vehicle, characterized by, The application relates to an injection-molded mounting bracket, which is arranged at the connection position of a plurality of aluminum bars and comprises a mounting groove arranged in the same direction as the aluminum bars for mounting the aluminum bars, a limiting groove arranged at the lower end of the mounting groove, and a mounting hole connected with the mounting groove, wherein the diameter of the mounting hole is larger than that of the limiting groove. The mounting nut is integrally injection-molded with the injection-molded mounting bracket, and comprises a supporting part embedded in the mounting hole and a mounting part embedded in the limiting groove. The bolt comprises a limiting part and a threaded part, wherein the lower end of the limiting part comprises a limiting surface for limiting the upper end of the aluminum bar. The threaded part penetrates through the plurality of aluminum bars, so that the limiting surface and the supporting surface jointly limit the plurality of aluminum bars along the axial direction, and the lower end of the threaded part is embedded in the mounting part and is in threaded connection with the mounting part. The outer wall of the mounting part is provided with a plurality of stop parts along the axial direction, the outer wall of the stop part is provided with a plurality of racks along the circumferential direction, the side wall of the limiting groove is provided with a rack groove corresponding to the stop part along the outward recessing direction, and the rack is embedded in the inner part of the rack groove.
2. The aluminum electric connection structure of a new energy vehicle according to claim 1, characterized in that: The bottom surface of the mounting groove is provided with a first positioning column and a second positioning column corresponding to the aluminum bar on both sides of the mounting hole.
3. The aluminum power distribution connection structure of a new energy vehicle according to claim 2, characterized in that: The aluminum bar arranged at the lower end is provided with a first positioning through hole corresponding to the first positioning column, and the upper end of the first positioning column is embedded in the inner part of the first positioning through hole.
4. The aluminum electric connection structure of a new energy vehicle according to claim 3, characterized in that: The aluminum bar arranged at the upper end is provided with a second positioning through hole corresponding to the second positioning column, and the upper end of the second positioning column is embedded in the inner part of the second positioning through hole.
5. The aluminum electric connection structure of a new energy vehicle according to claim 3, characterized in that: The bolt further comprises an elastic part and a bolt head, the elastic part is arranged between the bolt head and the limiting part, the upper end of the elastic part abuts against the bolt head, and the lower end of the elastic part abuts against the upper end of the limiting part so that the limiting surface abuts against the upper end surface of the aluminum bar.
6. The aluminum electric connection structure of a new energy vehicle according to claim 1, characterized in that: The second positioning column and the first positioning column have a height difference.
7. The aluminum power distribution connection structure of a new energy vehicle according to claim 3, characterized in that: The aluminum bar comprises an aluminum bar body and a plating layer, the plating layer comprises a nickel layer and a tin layer in sequence, the thickness of the nickel layer is 2-6 mu m, and the thickness of the tin layer is 3-8 mu m.
8. The aluminum electric connection structure of a new energy vehicle according to claim 1, characterized in that: The material of the aluminum bar body is aluminum, and the material includes but is not limited to Al6101 and Al1060.
9. The aluminum power distribution connection structure of a new energy vehicle according to claim 8, characterized in that: