A copper-aluminum connection device and a vehicle having the same.
By designing an overflow zone in the copper-aluminum connection device, the problem of exposed welding overflow was solved, enabling a highly efficient welding process, reducing production costs and improving production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGZHOU AUTOMOBILE GROUP CO LTD
- Filing Date
- 2025-07-02
- Publication Date
- 2026-07-03
AI Technical Summary
Existing copper-aluminum connection devices suffer from solder overflow during welding, leading to additional production steps and increased production costs.
A copper-aluminum connection device was designed, which includes an overflow area to contain welding overflow. The copper and aluminum materials are connected by ultrasonic welding. The overflow area covers the welding overflow, avoiding the need for cleaning steps.
This reduces the number of welding overflow cleaning steps, improves production efficiency and reduces production costs, while ensuring connection strength and the speed of automated production.
Smart Images
Figure CN224444844U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of vehicle body technology, and more particularly to a copper-aluminum connection device and a vehicle having the same. Background Technology
[0002] In the existing copper-aluminum connection device, when welding the busbar to the connector, the solder overflow at the welding point will be exposed around the connector. In order to ensure product quality, the solder overflow needs to be cleaned, which increases the production steps of the copper-aluminum connection device and is not conducive to reducing production costs. Utility Model Content
[0003] This application provides a copper-aluminum connection device and a vehicle having the same, with the aim of reducing production costs.
[0004] According to a first aspect of this application, a copper-aluminum connecting device includes: a first busbar having a mounting hole extending through it in a first direction, the first direction being the thickness direction of the first busbar; and a connector including: a body and a boss, the body being formed as a column extending in the first direction and passing through the mounting hole; the boss being connected to one end of the body in the first direction and extending in a ring shape in the circumferential direction of the body, the surface of the boss facing the first busbar having a welding surface and an overflow area, the overflow area being located outside the welding surface in the radial direction of the boss, the overflow area extending in the circumferential direction of the boss, and the overflow area being adapted to receive welding overflow generated when the welding surface is welded to the first busbar.
[0005] According to the copper-aluminum connection device of the first aspect of this application, by setting an overflow area, the overflow area can cover the welding overflow, eliminating the need to clean the welding overflow, thereby reducing cleaning steps, improving production efficiency, and reducing production costs.
[0006] According to some embodiments of this application, the connector is ultrasonically welded to the first busbar.
[0007] In this embodiment, ultrasonic welding is fast and quick, enabling high-speed automated production. At the same time, ultrasonic welding can ensure the connection strength between the connector and the first busbar, effectively preventing the connector from separating from the first busbar.
[0008] According to some embodiments of this application, the boss includes: a first frustum and a second frustum arranged along the first direction and coaxially disposed, the second frustum being connected between the first frustum and the main body, the diameter of the second frustum being smaller than the diameter of the first frustum, and the outer peripheral surface of the second frustum and the end face of the first frustum facing the main body cooperating to enclose the overflow area.
[0009] In this embodiment, the overflow area structure is simple and easy to process. At the same time, it can ensure that the welding overflow can be completely covered, so that there is no need to clean the welding overflow.
[0010] According to some embodiments of this application, the overflow area extends in a ring shape along the circumference of the boss, and / or the overflow area includes a plurality of overflow areas, which are arranged at intervals along the circumference of the boss.
[0011] In this embodiment, since the location of the welding overflow during the welding process is uncertain, the overflow area extends in a ring shape along the circumference of the boss. This ensures that the overflow area can accommodate welding overflow from any location, eliminating the need for cleaning the welding overflow and improving the rationality of the overflow area setting. In addition, there are multiple overflow areas, and multiple grooves can cover multiple overflow locations, thereby effectively accommodating the welding overflow within the overflow area.
[0012] According to some embodiments of this application, the width of the overflow area in the radial direction of the boss is in the range of 1.5mm-2.5mm.
[0013] In this embodiment, the width of the overflow area is limited, which ensures that the boss covers the area in the radial direction. This ensures that the welding overflow in the overflow area can be completely covered by the boss, thus eliminating the need to clean the welding overflow.
[0014] According to some embodiments of this application, the depth of the overflow area in the axial direction of the boss is in the range of 0.3mm-0.7mm.
[0015] In this embodiment, the depth of the overflow area is limited to ensure that the overflow area has sufficient space to accommodate the welding overflow, thereby preventing the overflow area from overflowing into the shielding area of the boss.
[0016] According to some embodiments of this application, in the thickness direction of the first electric busbar, the length of the main body is greater than or equal to the thickness of the first electric busbar.
[0017] In this embodiment, the main body can be passed through the mounting hole, thus ensuring that the copper-aluminum connecting device can be connected to other structures. Simultaneously, it facilitates the fixing of the first busbar and the connector by other structures, such as fasteners. Furthermore, the connector can withstand the pressure of the screw torque without creeping.
[0018] According to some embodiments of this application, the first busbar is made of aluminum and the connector is made of copper, or the first busbar is made of copper and the connector is made of aluminum.
[0019] In this embodiment, aluminum busbars have low density, making them suitable for weight-sensitive applications, such as new energy vehicles and aerospace. Copper connectors have excellent conductivity, which can optimize the contact resistance of critical connection points and reduce the risk of overheating. And / or, copper busbars have higher conductivity, making them suitable for resistance-sensitive high-precision or high-frequency scenarios, such as precision instruments and communication base stations. Aluminum connectors have low processing costs, making them suitable for mass production of complex-shaped connectors.
[0020] According to some embodiments of this application, the connector is provided with a fixing hole that extends through the connector along the axial direction of the body, and a fastener is adapted to pass through the fixing hole to securely connect the first electric busbar to the vehicle body.
[0021] In this embodiment, the copper-aluminum connecting device can be connected to the vehicle body using fasteners, which facilitates the fixing of the copper-aluminum connecting device to the vehicle body and ensures the connection strength between the copper-aluminum connecting device and the vehicle body, effectively preventing the aluminum strip from separating from the vehicle body.
[0022] The vehicle according to the second aspect of this application includes the copper-aluminum connecting device according to the first aspect of this application.
[0023] According to the second aspect of this application, the vehicle is equipped with the copper-aluminum connection device described above according to the embodiment of this application. By setting an overflow area, the overflow area can cover the welding overflow, eliminating the need to clean the welding overflow, thereby reducing cleaning steps, improving production efficiency, and reducing production costs. Attached Figure Description
[0024] Figure 1 This is a schematic diagram of a copper-aluminum connection device provided in an embodiment of this application;
[0025] Figure 2 yes Figure 1 A schematic diagram of one angle of the connector shown;
[0026] Figure 3 yes Figure 1 A schematic diagram of the connector shown from another angle.
[0027] Explanation of reference numerals in the attached figures:
[0028] 100. Copper-aluminum connection device;
[0029] 10. First busbar; 11. Mounting hole;
[0030] 20. Connector; 21. Main body; 22. Boss; 221. Welding surface; 222. Overflow area; 23. Fixing hole;
[0031] 201. First frustum; 202. Second frustum. Detailed Implementation
[0032] To make the technical problems, technical solutions, and beneficial effects solved by this application clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.
[0033] The following is for reference. Figures 1-3 This application describes a copper-aluminum connection device 100 according to an embodiment of the present application.
[0034] The copper-aluminum connecting device 100 provided in this application embodiment, such as Figures 1-3 As shown, it includes: a first busbar 10 and a connector 20.
[0035] Specifically, the first busbar 10 is provided with a first direction (e.g., Figure 1 The mounting hole 11 of the first busbar 10 (shown in the vertical direction) penetrates through the first busbar 10, and the first direction is the thickness direction of the first busbar 10; the connector 20 includes: a main body 21 and a boss 22, the main body 21 is formed as a column extending along the first direction and passes through the mounting hole 11; the boss 22 is connected to one end of the main body 21 in the first direction (e.g., in the vertical direction). Figure 1 The upper end of the main body 21 shown) extends in a ring shape along the circumference of the main body 21. The surface of the boss 22 facing the first electric bus 10 has a welding surface 221 and an overflow area 222. The overflow area 222 is located outside the welding surface 221 in the radial direction of the boss 22. The overflow area 222 extends along the circumferential direction of the boss 22. The overflow area 22 is adapted to contain the welding overflow generated when the welding surface 221 is welded to the first electric bus 10.
[0036] For example, such as Figure 1 , Figure 2 and Figure 3 As shown, the first busbar 10 is provided with a mounting hole 11 that runs through the first busbar 10 in the vertical direction. The vertical direction is the thickness direction of the first busbar 10. The main body 21 extends in the vertical direction. The main body 21 can be a cylinder or a square column. The main body 21 is inserted into the mounting hole 11 from top to bottom. The boss 22 is connected to the upper end of the main body 21 and extends in a ring shape along the circumference of the main body 21. The lower surface of the boss 22 has a welding surface 221 and an overflow area 222. The first busbar 10 and the connector 20 are welded together on the welding surface 221.
[0037] Currently, electric vehicles connect to the battery pack via a first electric gate 10 and a connector 20. To prevent electrochemical corrosion and torque reduction issues caused by directly screwing the first electric gate 10 and connector 20 together, ultrasonic welding is commonly used to fuse them. However, in the prior art, the surface of the connector 20 is directly attached to the surface of the first electric gate 10, causing weld spatter to overflow from the periphery of the connector 20, requiring further processing and hindering production efficiency.
[0038] The copper-aluminum connecting device 100 of this application, by setting an overflow area 222, allows welding overflow to occur when the first electric busbar 10 is welded to the connector 20. During welding, welding overflow occurs radially outward along the boss 22. Therefore, the welding overflow overflows into the overflow area 222. The overflow area 222 is reasonably positioned, providing space for the welding overflow. At the same time, the boss 22 can cover the welding overflow, eliminating the need for cleaning. This reduces the steps required to clean the welding overflow, improves production efficiency, and lowers production costs.
[0039] According to the copper-aluminum connecting device 100 of the present application embodiment, by setting an overflow area 222, the overflow area 222 can cover the welding overflow, eliminating the need to clean the welding overflow, thereby reducing cleaning steps, improving production efficiency, and reducing production costs.
[0040] In some embodiments of this application, such as Figure 1 As shown, the connector 20 and the first electric busbar 10 are connected by ultrasonic welding.
[0041] Therefore, ultrasonic welding has a short time and high speed, which can be used for high-speed automated production. At the same time, ultrasonic welding can ensure the connection strength between the connector 20 and the first electric busbar 10, and effectively prevent the connector 20 from separating from the first electric busbar 10.
[0042] Preferably, the first electric busbar 10 and the connector 20 can be connected by linear or torque ultrasonic welding, which can effectively solve the problem of stress relaxation at the connection between the first electric busbar 10 and the connector 20.
[0043] In some embodiments of this application, such as Figure 2 As shown, the boss 22 includes: along a first direction (such as...) Figure 2 A first frustum 201 and a second frustum 202, arranged coaxially in the vertical direction (as shown), are connected between the first frustum 201 and the main body 21. The diameter of the second frustum 202 is smaller than the diameter of the first frustum 201. The outer circumferential surface of the second frustum 202 is parallel to the end face of the first frustum 201 facing the main body 21 (as shown). Figure 2The lower end face of the first truncated cone shown in the figure encloses the overflow area 222.
[0044] Therefore, this type of overflow area 222 has a simple structure, is easy to process, and can ensure that all welding overflow is covered, thus eliminating the need for cleaning. Furthermore, it allows excess welding overflow to be smoothly discharged radially into the overflow area 222, reducing burr residue and improving product surface quality.
[0045] For example, such as Figure 2 As shown, the first frustum 201 is arranged in a plane perpendicular to the vertical direction, and the second frustum 202 is arranged in a plane perpendicular to the vertical direction. The second frustum 202 is connected between the first frustum 201 and the main body 21, and the first frustum 201 and the second frustum 202 are coaxially arranged. The outer peripheral surface of the second frustum 202 and the lower end face of the first frustum 201 cooperate to enclose the overflow area 222.
[0046] In some embodiments of this application, such as Figure 2 As shown, the overflow area 222 extends in a ring shape along the circumference of the boss 22, and / or, the overflow area 222 includes multiple overflow areas, that is, the overflow area 222 may include two, three or four or more, and the multiple overflow areas 222 are arranged at intervals along the circumference of the boss 22.
[0047] Since the location of welding overflow during the welding process is uncertain, the overflow area 222 extends in a ring shape along the circumference of the boss 22. This ensures that the overflow area 222 can accommodate welding overflow from any location, eliminating the need for cleaning the welding overflow and improving the rationality of the overflow area 222's design. Furthermore, there are multiple overflow areas 222, and multiple grooves can cover multiple overflow locations, effectively accommodating the welding overflow within the overflow area 222.
[0048] For example, such as Figure 2 As shown, the overflow area 222 extends in a ring shape along the circumference of the boss 22.
[0049] In some embodiments of this application, such as Figure 2 and Figure 3 As shown, the width of the overflow area 222 in the radial direction of the boss 22 is in the range of 1.5mm-2.5mm.
[0050] Therefore, by limiting the width of the overflow area 222, the area covered by the boss 22 in the radial direction can be guaranteed, thus ensuring that the welding overflow in the overflow area 222 can be completely covered by the boss 22, so that there is no need to clean the welding overflow. At the same time, it can also ensure that the welding overflow can be discharged normally into the welding area 222.
[0051] It should be noted that if the width of the overflow area 222 is less than 1.5mm, the radial coverage of the boss 22 cannot be guaranteed, which will cause the welding overflow to be exposed from the boss 22. Therefore, the width of the overflow area 222 must be greater than or equal to 1.5mm. If the width of the overflow area 222 is greater than 2.5mm, the boss 22 will not have space to be arranged in the radial direction, which will cause the overflow area 222 to be unable to be arranged. Therefore, the width of the overflow area 222 must be less than or equal to 2.5mm.
[0052] Preferably, the width of the overflow area 222 in the radial direction of the boss 22 can be 1.5mm, 1.6mm, 1.7mm, 1.8mm, 1.9mm, 2mm, 2.1mm, 2.2mm, 2.3mm, 2.4mm or 2.5mm.
[0053] In some embodiments of this application, such as Figure 2 and Figure 3 As shown, in the axial direction of the boss 22, the depth of the overflow area 222 is in the range of 0.3mm-0.7mm.
[0054] Therefore, limiting the depth of the overflow area 222 can ensure that the overflow area 222 has sufficient space to accommodate the welding overflow, thereby preventing the overflow area 222 from overflowing into the shielding range of the boss 22. At the same time, the overflow area 222 of a reasonable depth can evenly distribute the mold closing pressure, avoid local stress concentration, and reduce the wear of the parting surface.
[0055] Preferably, the depth of the overflow area 222 in the axial direction of the boss 22 can be 0.3mm, 0.4mm, 0.5mm, 0.6mm or 0.7mm.
[0056] It should be noted that if the depth of the overflow area 222 is less than 0.3mm, the volume of the overflow area 222 cannot be guaranteed, which will cause the welding overflow to spill from the boss 22 to the radial outer side of the boss 22. Therefore, the depth of the overflow area 222 must be greater than or equal to 0.3mm. If the depth of the overflow area 222 is greater than 0.7mm, it will affect the structural strength of the boss 22. Therefore, the depth of the overflow area 222 must be less than or equal to 0.7mm.
[0057] In some embodiments of this application, such as Figure 1 and Figure 2 As shown, in the thickness direction of the first electric bus 10 (e.g.) Figure 1 In the thickness direction of the first busbar 10 shown, the length of the main body 21 is greater than or equal to the thickness of the first busbar 10.
[0058] This ensures that the main body 21 can pass through the mounting hole 11, thereby allowing the copper-aluminum connecting device 100 to connect with other structures. It also facilitates the fixing of the first busbar 10 and the connector 20 by other structures, such as fasteners. Furthermore, the connector 20 can withstand the pressure of the screw torque without creeping.
[0059] Preferably, the difference between the length of the main body 21 and the thickness of the first electric busbar 10 can be 0 mm, 0.1 mm, 0.2 mm, 0.3 mm or 0.4 mm.
[0060] In some embodiments of this application, such as Figure 1 and Figure 2 As shown, the first busbar 10 is made of aluminum, and the connector 20 is made of copper.
[0061] Therefore, aluminum busbars have a low density, making them suitable for weight-sensitive applications such as new energy vehicles and aerospace. Copper connectors have excellent conductivity, which can optimize the contact resistance of critical connection points and reduce the risk of overheating.
[0062] Furthermore, such as Figure 1 and Figure 2 As shown, the first busbar 10 is made of copper, and the connector 20 is made of aluminum.
[0063] Therefore, copper busbars have higher conductivity and are suitable for high-precision or high-frequency applications that are sensitive to resistance, such as precision instruments and communication base stations. Aluminum connectors 20 have low processing costs and are suitable for mass production of connectors 20 with complex shapes.
[0064] In some embodiments of this application, such as Figure 1 and Figure 2 As shown, the connector 20 is provided with a fixing hole 23, which extends through the connector 20 along the axial direction of the main body 21. The fastener is adapted to pass through the fixing hole 23 to securely connect the first electric bus 10 to the vehicle body.
[0065] Therefore, the copper-aluminum connecting device 100 can be connected to the vehicle body by fasteners, which can facilitate the fixing of the copper-aluminum connecting device 100 to the vehicle body, and also ensure the connection strength between the copper-aluminum connecting device 100 and the vehicle body, effectively preventing the aluminum strip from separating from the vehicle body.
[0066] For example, such as Figure 1 and Figure 2 As shown, the connector 20 is provided with a fixing hole 23 that runs through the connector 20 in the vertical direction. The fastener is a bolt, which passes through the fixing hole 23 from top to bottom to fix the copper-aluminum connector 100 to the vehicle body.
[0067] The vehicle provided in this application embodiment includes the copper-aluminum connecting device 100 described above according to this application embodiment.
[0068] According to the vehicle of the present application embodiment, by setting the copper-aluminum connection device 100 according to the present application embodiment, by setting the overflow area 222, the overflow area 222 can cover the welding overflow, eliminating the need to clean the welding overflow, thereby reducing cleaning steps, improving production efficiency, and reducing production costs.
[0069] In this application, "multiple" refers to two or more.
[0070] In this application, unless otherwise expressly defined, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0071] The terms “first,” “second,” “third,” “fourth,” etc., in this application (if present) are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.
[0072] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.
[0073] Unless otherwise specified, all steps in this application may be performed sequentially or randomly. For example, if the method includes steps A and B, it means that the method may include steps A and B performed sequentially, or it may include steps B and A performed sequentially. For example, if the method may also include step C, it means that step C may be added to the method in any order. For example, the method may include steps A, B, and C, or it may include steps A, C, and B, or it may include steps C, A, and B, etc.
[0074] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.
Claims
1. A copper-aluminum connection device (100), characterized in that, include: A first busbar (10) is provided with a mounting hole (11) that passes through the first busbar (10) along a first direction, the first direction being the thickness direction of the first busbar (10). The connector (20) includes a body (21) and a boss (22). The body (21) is formed as a column extending along the first direction and passes through the mounting hole (11). The boss (22) is connected to one end of the body (21) in the first direction and extends in a ring shape along the circumference of the body (21). The surface of the boss (22) facing the first busbar (10) has a welding surface (221) and an overflow area (222). The overflow area (222) is located outside the welding surface (221) in the radial direction of the boss (22). The overflow area (222) extends along the circumferential direction of the boss (22). The overflow area (222) is adapted to receive welding overflow generated when the welding surface (221) is welded to the first busbar (10).
2. The copper-aluminum connection device (100) according to claim 1, characterized in that The connector (20) is connected to the first electric bus (10) by ultrasonic welding.
3. The copper-aluminum connection device (100) according to claim 1, characterized in that The boss (22) includes a first frustum (201) and a second frustum (202) arranged along the first direction and coaxially disposed. The second frustum (202) is connected between the first frustum (201) and the main body (21). The diameter of the second frustum (202) is smaller than the diameter of the first frustum (201). The outer peripheral surface of the second frustum (202) and the end face of the first frustum (201) facing the main body (21) cooperate to enclose the overflow area (222).
4. The copper-aluminum connection device (100) according to claim 1, characterized in that The overflow area (222) extends in a ring shape along the circumference of the boss (22), and / or the overflow area (222) includes a plurality of overflow areas (222) arranged at intervals along the circumference of the boss (22).
5. The copper-aluminum connection arrangement (100) according to any one of claims 1-4, characterized in that, In the radial direction of the boss (22), the width of the overflow area (222) is in the range of 1.5mm-2.5mm.
6. The copper-aluminum connecting device (100) according to any one of claims 1-4, characterized in that, In the axial direction of the boss (22), the depth of the overflow area (222) is in the range of 0.3mm-0.7mm.
7. The copper-aluminum connection device (100) of claim 1, wherein, In the thickness direction of the first electric busbar (10), the length of the main body (21) is greater than or equal to the thickness of the first electric busbar (10).
8. The copper-aluminum connection device (100) of claim 1, wherein, The first busbar (10) is made of aluminum and the connector (20) is made of copper, or the first busbar (10) is made of copper and the connector (20) is made of aluminum.
9. The copper-aluminum connection device (100) of claim 1, wherein, The connector (20) is provided with a fixing hole (23), which extends through the connector (20) along the axial direction of the body (21). Fasteners are adapted to pass through the fixing hole (23) to securely connect the first electric bus (10) to the vehicle body.
10. A vehicle characterized by comprising: Includes the copper-aluminum connection device (100) according to any one of claims 1-9.