Polymer diffusion composite welded copper-aluminum busbar

Abstract

This utility model relates to the field of copper-aluminum busbar technology, specifically a polymer diffusion composite welded copper-aluminum busbar, comprising: a copper busbar, an aluminum busbar, and a nickel sheet. The nickel sheet is disposed between the copper busbar and the aluminum busbar to form a welding surface. The copper busbar and the aluminum busbar have a pressure-applying surface relative to the welding surface. A welding layer with polymer material is attached to the welding surface. The nickel sheet is metallurgically connected between the copper busbar and the aluminum busbar through the polymer material. With the assistance of pressure from the pressure-applying surface, the polymer material is diffused and compositely connected between the copper busbar and the aluminum busbar. By using the polymer material as an intermediate welding layer, metallurgical bonding can be achieved under relatively low temperature conditions by utilizing the melting point characteristics of copper and aluminum, effectively avoiding the heat-affected zone problem caused by traditional fusion welding. Furthermore, by applying controllable pressure through the pressure-applying surface, the uniform diffusion of the polymer material at the copper-aluminum interface is promoted, ensuring the density and continuity of the connection interface. This allows the polymer material to form a strong bond at the welding surface, inhibiting compound formation, resulting in a compact structure and strong practicality.

Description

Technical Field

[0001] This utility model relates to the field of copper-aluminum busbar technology, specifically a polymer diffusion composite welded copper-aluminum busbar. Background Technology

[0002] Copper is a metal with excellent electrical and thermal conductivity, widely used in various industries. However, due to its high density, products made of copper are heavy, causing significant inconvenience in transportation and use. Especially with the severe shortage of copper resources, the procurement cost of copper raw materials remains high. Aluminum is the second most conductive and thermally conductive metal after copper. Although its conductivity is only two-thirds that of copper, its density is only one-third that of copper. Because of its lighter weight, it is often chosen by the power and electronics industries.

[0003] Existing copper-aluminum composite bars are welded using copper-aluminum composite polymers. However, due to the different properties of the two materials, there is molecular repulsion during the bonding process, which creates gaps and increases the risk of cracking in the copper-aluminum bond, hindering its development. Utility Model Content

[0004] To address the aforementioned problems, this utility model provides a polymer diffusion composite welded copper-aluminum busbar, which solves the problem that existing copper-aluminum composite busbars, when welded with copper-aluminum composite polymers, suffer from the risk of cracking due to the molecular repulsion and gaps generated during bonding caused by the different properties of the two materials, hindering their development.

[0005] The technical solution adopted in this utility model is as follows: it includes a copper busbar, an aluminum busbar, and a nickel sheet. The nickel sheet is disposed between the copper busbar and the aluminum busbar to form a welding surface. The upper and lower surfaces of the copper busbar are provided with pressure surfaces relative to the welding surface. A welding layer is disposed on the welding surface, and a polymer material is attached to the welding layer. The melting point of the polymer material is lower than that of the copper busbar and the aluminum busbar. The nickel sheet is metallurgically connected between the copper busbar and the aluminum busbar by the polymer material, and is further pressurized by the pressure surface to diffuse and composite the polymer material between the copper busbar and the aluminum busbar.

[0006] A further improvement to the above solution is that the copper busbar and the aluminum busbar are provided with mounting portions relative to the nickel sheet, and the mounting portions are provided with mounting holes.

[0007] A further improvement to the above scheme is that the widths of the copper busbar and the aluminum busbar are the same.

[0008] A further improvement to the above scheme is that the aluminum busbar and the copper busbar are lap-welded using Sanhe welding wire.

[0009] A further improvement to the above scheme is that the copper busbar is made of copper or a copper alloy, and the aluminum busbar is made of aluminum or an aluminum alloy.

[0010] A further improvement to the above scheme is that the welding area of ​​the welding surface is larger than the area of ​​the copper busbar.

[0011] A further improvement to the above scheme is that the welding surface is a rough surface.

[0012] A further improvement to the above scheme is that the melting point of the nickel sheet is lower than that of the copper busbar and the aluminum busbar.

[0013] The beneficial effects of this utility model are:

[0014] Compared to existing copper-aluminum busbars, this utility model uses a polymer material as the intermediate welding layer. Utilizing the polymer material's lower melting point than copper and aluminum, metallurgical bonding can be achieved under relatively low-temperature conditions, effectively avoiding the heat-affected zone problem caused by traditional fusion welding. This maintains the mechanical properties of the base material while significantly reducing energy consumption. Furthermore, by applying controllable pressure to the pressure surface, the polymer material is promoted to diffuse evenly at the copper-aluminum interface, ensuring the density and continuity of the connection interface. This allows the polymer material to form a strong bond at the welding surface, effectively inhibiting the formation of intermetallic compounds between copper and aluminum. The structure is compact and highly practical. Attached Figure Description

[0015] Figure 1 This is a perspective view of the polymer diffusion composite welded copper-aluminum busbar of this utility model;

[0016] Figure 2 This is an exploded view of the polymer diffusion composite welded copper-aluminum busbar of this utility model.

[0017] Explanation of reference numerals in the attached diagram: 10 copper busbar, 11 pressure surface;

[0018] Aluminum strip 20, mounting part 21, mounting hole 22;

[0019] Nickel sheet 30, welding surface 31, welding layer 32. Detailed Implementation

[0020] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0021] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0023] like Figures 1-2 As shown in the embodiment of this utility model, a polymer diffusion composite welded copper-aluminum busbar includes: a copper busbar 10, an aluminum busbar 20, and a nickel sheet 30. The nickel sheet 30 is disposed between the copper busbar 10 and the aluminum busbar 20 to form a welding surface 31. The copper busbar 10 and its upper and lower surfaces are provided with pressure surfaces 11 relative to the welding surface 31. A welding layer 32 is disposed on the welding surface 31, and a polymer material is attached to the welding layer 32. The melting point of the polymer material is lower than that of the copper busbar 10 and the aluminum busbar 20. The nickel sheet 30 is metallurgically connected between the copper busbar 10 and the aluminum busbar 20 through the polymer material, and is further pressurized by the pressure surface 11 to diffuse and compositely connect the polymer material between the copper busbar 10 and the aluminum busbar 20. In this embodiment, a polymer material is used as the intermediate welding layer 32. Taking advantage of its lower melting point than copper and aluminum, metallurgical bonding can be achieved under relatively low temperature conditions, effectively avoiding the heat-affected zone problem caused by traditional fusion welding. This maintains the mechanical properties of the base material and significantly reduces energy consumption. Furthermore, by applying controllable pressure through the pressure surface 11, the polymer material is promoted to diffuse evenly at the copper-aluminum interface, ensuring the density and continuity of the connection interface. This allows the polymer material to form a strong bond at the welding surface 31, effectively suppressing the formation of intermetallic compounds between copper and aluminum. The structure is compact and highly practical.

[0024] like Figures 1 to 2 As shown, the copper busbar 10 and aluminum busbar 20 are provided with mounting portions 21 relative to the nickel sheet 30, and the mounting portions 21 are provided with mounting holes 22. In this embodiment, the mounting portions 21 are provided on the nickel sheet 30 of the copper busbar 10 and aluminum busbar 20, and the mounting holes 22 are opened on the mounting portions 21, which facilitates fixed connection with other electrical components and improves the assembly convenience of the product.

[0025] The copper busbar 10 and the aluminum busbar 20 have the same width. In this embodiment, by making the copper busbar 10 and the aluminum busbar 20 the same size, the problems of insufficient interface bonding strength and high resistivity of the copper-aluminum busbar 20 are solved, and the mechanical and electrical properties of the copper-aluminum busbar 20 are effectively improved.

[0026] The aluminum busbar 20 and the copper busbar 10 are lap-welded using Sanhe welding wire. In this embodiment, a reliable connection between dissimilar metals, copper and aluminum, is achieved through a polymer diffusion composite welding process. By using polymer materials as a diffusion medium, a metallurgical bonding layer is formed at the copper-aluminum interface under specific temperature and pressure conditions, effectively solving the problem of insufficient bonding strength caused by differences in metal properties in traditional welding.

[0027] The copper busbar 10 is made of copper or a copper alloy, and the aluminum busbar 20 is made of aluminum or an aluminum alloy. In this embodiment, the copper busbar 10 is made of pure copper or a copper alloy, and the aluminum busbar 20 is made of pure aluminum or an aluminum alloy. Through a polymer diffusion composite welding process, the two dissimilar metals form a strong metallurgical bond.

[0028] The copper busbar 10 can be made of copper foil, copper braided mesh, copper wire, or flexible flat cable. In this embodiment, a metallurgical bonding layer is formed between the copper busbar 10 (including copper foil, copper braided mesh, copper wire, and flexible flat cable) and the aluminum busbar 20 through diffusion fusion of polymer materials. This effectively solves the interface brittleness problem commonly encountered in traditional welding and enhances the service life of the copper busbar 10.

[0029] The aluminum busbar 20 can be aluminum foil, aluminum braided mesh, aluminum wire, or aluminum braided strip. In this embodiment, when the busbar, including the aluminum busbar 20, aluminum foil, aluminum braided mesh, aluminum wire, and aluminum braided strip, is connected to the copper busbar 10, the copper and aluminum atoms can penetrate each other, forming a metallurgical bonding layer at the interface. This effectively avoids the problem of brittle phase formation in the heat-affected zone caused by traditional fusion welding.

[0030] The area of ​​the welding surface 31 is larger than the area of ​​the copper busbar 10. In this embodiment, the enlarged welding contact surface significantly increases the effective bonding area of ​​the copper-aluminum interface, allowing metal atoms to obtain more diffusion space under high temperature and high pressure conditions, effectively dispersing welding stress and avoiding local stress concentration problems caused by differences in thermal expansion coefficients.

[0031] Welding surface 31 is a rough surface. In this embodiment, the rough surface structure increases the contact area, making it easier for copper and aluminum materials to achieve atomic-level diffusion bonding under high temperature and pressure, effectively improving the metallurgical bonding strength of the welding interface. The micro-uneven surface structure can mechanically interlock to form multiple anchoring effects, which can accommodate stress deformation generated during welding, making it highly practical.

[0032] The melting point of nickel sheet 30 is lower than that of copper busbar 10 and aluminum busbar 20. In this embodiment, because the melting point of nickel sheet 30 is significantly lower than that of the base materials of copper busbar 10 and aluminum busbar 20, grain coarsening of the base material can be avoided, the original mechanical properties of copper and aluminum busbar 20 can be maintained, the risk of thermal deformation can be effectively reduced, and the practicality is strong.

[0033] A polymer diffusion composite welded copper-aluminum busbar includes: a copper busbar 10, an aluminum busbar 20, and a nickel sheet 30. The nickel sheet 30 is disposed between the copper busbar 10 and the aluminum busbar 20 to form a welding surface 31. The upper and lower surfaces of the copper busbar 10 are provided with pressure surfaces 11 relative to the welding surface 31. A welding layer 32 is disposed on the welding surface 31, and a polymer material is attached to the welding layer 32. The melting point of the polymer material is lower than that of the copper busbar 10 and the aluminum busbar 20. The nickel sheet 30 is metallurgically connected between the copper busbar 10 and the aluminum busbar 20 through the polymer material, and is further pressurized by the pressure surface 11 to diffuse and compositely connect the polymer material between the copper busbar 10 and the aluminum busbar 20. In this embodiment, a polymer material is used as the intermediate welding layer 32. Taking advantage of its lower melting point than copper and aluminum, metallurgical bonding can be achieved under relatively low temperature conditions, effectively avoiding the heat-affected zone problem caused by traditional fusion welding. This maintains the mechanical properties of the base material and significantly reduces energy consumption. Furthermore, by applying controllable pressure through the pressure surface 11, the polymer material is promoted to diffuse evenly at the copper-aluminum interface, ensuring the density and continuity of the connection interface. This allows the polymer material to form a strong bond at the welding surface 31, effectively suppressing the formation of intermetallic compounds between copper and aluminum. The structure is compact and highly practical.

[0034] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A polymer diffusion composite welded copper-aluminum busbar, characterized in that, include: The system comprises a copper busbar, an aluminum busbar, and a nickel sheet. The nickel sheet is disposed between the copper busbar and the aluminum busbar to form a welding surface. The upper and lower surfaces of the copper busbar are provided with pressure surfaces relative to the welding surface. A welding layer is disposed on the welding surface, and a polymer material is attached to the welding layer. The melting point of the polymer material is lower than that of the copper busbar and the aluminum busbar. The nickel sheet is metallurgically connected between the copper busbar and the aluminum busbar by the polymer material, and is further pressurized by the pressure surfaces to diffuse and composite the polymer material between the copper busbar and the aluminum busbar.

2. The polymer diffusion bonded copper aluminum busbar of claim 1, wherein: The copper busbar and aluminum busbar are provided with mounting portions relative to the nickel sheet, and the mounting portions are provided with mounting holes.

3. The polymer diffusion bonded copper-aluminum busbar of claim 2, wherein: The copper busbar and the aluminum busbar have the same width.

4. The polymer diffusion composite welded copper-aluminum busbar according to claim 3, characterized in that: The aluminum busbar and copper busbar are lap-welded using three welding wires.

5. The polymer diffusion bonded copper-aluminum busbar of claim 4, wherein: The copper busbar is made of copper or a copper alloy, and the aluminum busbar is made of aluminum or an aluminum alloy.

6. The polymer diffusion bonded copper aluminum busbar of claim 1, wherein: The welding area of ​​the welding surface is larger than the area of ​​the copper busbar.

7. The polymer diffusion bonded copper-aluminum busbar of claim 6, wherein: The welding surface is a rough surface.

8. The polymer diffusion bonded copper-aluminum busbar of claim 7, wherein: The melting point of the nickel sheet is lower than that of the copper busbar and the aluminum busbar.

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