A type of aluminum wire ultrasonic welding grounding hole terminal

Abstract

This utility model discloses an ultrasonic welding terminal for aluminum wire with a grounding hole, relating to the technical field of grounding hole terminals. When welding the grounding hole terminal to an aluminum wire, pitted dots are used to increase the welding area between the welding zone and the aluminum wire, thereby reducing connection resistance. Simultaneously, a heat-shrinkable sealing zone is provided between the terminal body and the welding zone. This heat-shrinkable sealing zone increases the area for sealing excess adhesive from the double-walled heat-shrink tubing, lengthening the sealing area. After the welding zone is connected to the aluminum wire, both the heat-shrinkable sealing zone and the welding zone are covered and sealed by the double-walled heat-shrink tubing, improving the sealing performance at the connection between the grounding hole terminal and the aluminum wire. This solves the technical problems of existing grounding hole terminals using crimping, resulting in a small crimping area and poor sealing at the connection.

Description

Technical Field

[0001] This utility model relates to the technical field of jumper hole type terminals, and in particular to an aluminum wire ultrasonic welding jumper hole type terminal. Background Technology

[0002] To address temporary external power needs of automobiles, such as temporary engine starting power for other vehicles with depleted batteries or temporary external lighting power, the vehicle's power supply circuit should have a jump-start function, allowing external power to be drawn from the vehicle's internal battery. This function is typically achieved using jump-start terminals in the electrical box. Simultaneously, the trend towards lightweighting in the automotive industry has led to the increasingly widespread use of aluminum wires in automotive wiring harnesses, with aluminum wires increasingly being used in jump-start circuits that carry higher currents. This has created a new demand for jump-start terminals: terminals capable of connecting aluminum wires.

[0003] However, existing grounding terminals generally use crimping to connect to aluminum wires. Due to the small crimping area, the connection resistance is high, the Joule heating at the connection point is large, and the temperature rise is high. When the connection between copper terminals and aluminum wires is crimped, the small crimping area and the short heat shrink tubing seal area make it easy for poor sealing to occur. In the case of poor sealing, there is a risk of potential corrosion. Utility Model Content

[0004] To address the shortcomings in the aforementioned background technology, this utility model proposes an ultrasonic welding terminal for aluminum wires with a grounding hole, which solves the technical problems of existing grounding hole terminals using crimping to connect to aluminum wires, resulting in a small crimping area and poor sealing at the connection point between the grounding hole terminal and the aluminum wire.

[0005] The technical solution of this utility model is implemented as follows: an aluminum wire ultrasonic welding grounding hole type terminal includes a terminal body, a grounding area integrally connected to the terminal body, a connection area for fixing the terminal and a heat shrink sealing area for increasing the overflow sealing area of ​​the double-wall heat shrink tubing integrally connected to the terminal body, and a welding area integrally connected to the heat shrink sealing area; the welding area is provided with pitted dots for increasing the welding area. The welding area of ​​the jumper terminal in this application is provided with pitted dots. When welding the jumper terminal to the aluminum wire, the pitted dots increase the welding area between the welding area and the aluminum wire, thereby reducing the connection resistance and increasing the pull-out force of the wire. At the same time, a heat-shrinkable sealing area is set between the terminal body and the welding area. The heat-shrinkable sealing area increases the area for sealing the excess adhesive of the double-walled heat-shrink tubing, thus lengthening the area for sealing the excess adhesive of the double-walled heat-shrink tubing. After the welding area is connected to the aluminum wire, both the heat-shrinkable sealing area and the welding area are covered and sealed by the double-walled heat-shrink tubing, isolating the intrusion of external moisture and other corrosive media, improving the sealing performance at the connection between the jumper terminal and the aluminum wire, and avoiding the problem of poor sealing at the connection between the jumper terminal and the aluminum wire. This solves the technical problems of existing jumper terminals and aluminum wires using crimping, which has a small crimping area and is prone to poor sealing at the connection.

[0006] The grounding hole type terminal of this application is formed by sheet metal stamping and bending. That is, the connection area, grounding area, welding area, heat shrink sealing area and terminal body on the grounding hole type terminal are integrally connected. This arrangement helps to reduce the resistance of the grounding hole type terminal of this application.

[0007] Preferably, the connection area and the grounding area are located at the top of the terminal body, and the heat-shrinkable sealing area is located at the bottom of the terminal body. This arrangement ensures a reasonable layout of the connection area, grounding area, and heat-shrinkable sealing area on the terminal body.

[0008] Preferably, the terminal body is a U-shaped body formed by bending sheet metal. The U-shaped body formed by bending sheet metal saves installation space and makes the electrical box for installing the jumper-hole type terminals of this application more compact.

[0009] Preferably, the heat-shrinkable sealing area is provided with a groove. The groove is used to avoid other components around the jumper terminal.

[0010] Preferably, the heat-shrinkable sealing area is provided with a stamped indentation indicator line three and an indentation indicator line two. The indentation indicator line two is provided to remind the operator not to allow the burrs at the end of the aluminum wire to extend beyond the indentation indicator line two during welding, thus preventing the burrs at the end of the aluminum wire from being too long and affecting the sealing performance of the double-walled heat-shrinkable tubing. A sufficiently long straight area is provided between the indentation indicator line three and the indentation indicator line two to ensure that the excess adhesive sealing area of ​​the double-walled heat-shrinkable tubing is sufficiently long to ensure sealing performance.

[0011] Preferably, the welding area is provided with a stamped indentation indicator line one, which is located below indentation indicator line two, and the groove is located between indentation indicator line three and indentation indicator line one. The groove is provided on both sides of the area where indentation indicator line three and indentation indicator line one are located to avoid other components around the jumper terminal. The area between indentation indicator line two and indentation indicator line one is reserved for the burr at the end of the aluminum wire after welding. Indentation indicator line two and indentation indicator line one together remind the operator not to allow the burr at the end of the wire to extend beyond the area between indentation indicator line two and indentation indicator line one during welding, to avoid the burr at the end of the aluminum wire being too long and affecting the sealing performance of the double-wall heat shrink tubing.

[0012] Preferably, the welding area is provided with a cut-resistant chamfer. The cut-resistant chamfer is provided to prevent the aluminum wire from being cut by the edge of the terminal block after welding.

[0013] Preferably, the welding area is provided with crack-resistant rounded corners. The crack-resistant rounded corners are provided to prevent the double-walled heat shrink tubing from being punctured by the sharp edges of the grounding hole type terminal during the heat shrinking process, which would lead to sealing failure.

[0014] Preferably, the connection area and the welding area are arranged perpendicularly at 90°; the connection area is provided with bolt holes. The 90° perpendicular arrangement of the connection area and the welding area allows the connection area to be fixed to the electrical box at a 90° angle perpendicular to the installation direction of the jumper terminal, which improves the stability of the jumper terminal installation. The bolt holes in the connection area facilitate bolt passage for connection. The bolt passes through the bolt hole of the jumper terminal, and then the jumper terminal and the conductive sheet are pressed tightly together and the position of the jumper terminal is fixed by tightening the nut, allowing the jumper terminal to connect to the circuit in the electrical box. During the tightening of the nut, under the rotational torque applied by the nut, the jumper terminal tends to rotate around the axis of the bolt hole. The jumper terminal relies on the small gap between the contour of the connection area and the electrical box to prevent rotation.

[0015] Preferably, the top of the jump-start area is a clamping portion for the jump-start clip to hold; the clamping portion is wavy. The clamping portion is designed to clamp with the jump-start clip so that power can be temporarily drawn from the vehicle's internal battery from outside the vehicle. The wavy shape of the clamping portion is to improve the firmness of the clamping portion and the jump-start clip, making it less likely for the jump-start clip to slip off the clamping portion, thus preventing the jump-start clip from slipping off the clamping portion and causing an unexpected power outage.

[0016] The beneficial effects of this utility model are: The welding area of ​​the jumper terminal in this application is provided with pitted dots. When welding the jumper terminal to the aluminum wire, the pitted dots increase the welding area between the welding area and the aluminum wire, thereby reducing the connection resistance and increasing the pull-out force of the wire. At the same time, a heat-shrinkable sealing area is set between the terminal body and the welding area. The heat-shrinkable sealing area increases the area of ​​double-wall heat-shrink tubing overflow seal, thus lengthening the double-wall heat-shrink tubing overflow seal area. After the welding area is connected to the aluminum wire, both the heat-shrinkable sealing area and the welding area are covered and sealed by double-wall heat-shrink tubing, isolating the intrusion of external moisture and other corrosive media, improving the sealing performance of the connection between the jumper terminal and the aluminum wire, and avoiding the situation where poor sealing is prone to occur at the connection between the jumper terminal and the aluminum wire. Attached Figure Description

[0017] To more clearly illustrate the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a perspective view of the present invention.

[0019] Figure 2 This is the front view of the present invention.

[0020] Figure 3 This is the left view of the present invention.

[0021] Figure 4 This is a top view of the present invention.

[0022] In the diagram, 1 is the connection area, 101 is the bolt hole, 2 is the electrical connection area, 201 is the clamping part, 3 is the welding area, 301 is the dent indicator line one, 302 is the pitted pit, 303 is the anti-cut chamfer, 304 is the anti-crack rounded corner, 4 is the heat shrink sealing area, 401 is the dent indicator line three, 402 is the groove, 403 is the dent indicator line two, and 5 is the terminal body. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] Example 1: An aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 and Figure 2 As shown, the device includes a terminal body 5, on which a grounding area 2 is integrally connected. The terminal body 5 also includes a connection area 1 for fixing the terminal and a heat-shrinkable sealing area 4 for increasing the sealing area of ​​the double-walled heat-shrinkable tubing. A welding area 3 is integrally connected to the heat-shrinkable sealing area 4. The welding area 3 has pitted pits 302 to increase the welding area. These pitted pits 302 are a type of metal surface defect, manifesting as pits or rough surfaces of varying sizes and shapes. The welding area 3 of the jumper terminal in this application is provided with pitted dots 302. When the jumper terminal is crimped with the aluminum wire, the pitted dots 302 increase the welding area between the welding area 3 and the aluminum wire, thereby reducing the connection resistance and increasing the pull-out force of the wire. At the same time, a heat-shrinkable sealing area 4 is provided between the terminal body 5 and the welding area 3. The heat-shrinkable sealing area 4 increases the area of ​​double-wall heat-shrink tubing overflow seal, thus lengthening the area of ​​double-wall heat-shrink tubing overflow seal. After the welding area 3 is connected to the aluminum wire, both the heat-shrinkable sealing area 4 and the welding area 3 are covered and sealed by double-wall heat-shrink tubing, isolating the intrusion of external moisture and other corrosive media, improving the sealing performance of the connection between the jumper terminal and the aluminum wire, and avoiding the situation where poor sealing is easy to occur at the connection between the jumper terminal and the aluminum wire. This solves the technical problems of existing jumper terminals and aluminum wires using crimping, which has a small crimping area and is prone to poor sealing at the connection between the jumper terminal and the aluminum wire.

[0025] The grounding hole type terminal of this application is formed by sheet metal stamping and bending. That is, the connection area 1, grounding area 2, welding area 3, heat shrink sealing area 4 and terminal body 5 on the grounding hole type terminal are integrally connected. This arrangement helps to reduce the resistance of the grounding hole type terminal of this application.

[0026] Example 2, based on Example 1, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 , Figure 2 and Figure 3As shown, the connection area 1 and the grounding area 2 are located at the top of the terminal body 5, and the heat-shrinkable sealing area 4 is located at the bottom of the terminal body 5. This arrangement is to ensure a reasonable layout of the connection area 1, the grounding area 2, and the heat-shrinkable sealing area 4 on the terminal body 5.

[0027] Example 3, based on Example 2, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the terminal body 5 is a U-shaped body formed by bending sheet metal. The U-shaped body formed by bending sheet metal is to save terminal installation space and make the electrical box for installing the jumper hole type terminals of this application more compact.

[0028] Example 4, based on Example 3, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 2 As shown, the heat-shrinkable sealing area 4 is provided with a groove 402. The groove 402 is provided on the heat-shrinkable sealing area 4 to avoid other components around the jumper terminal.

[0029] Example 5, based on Example 4, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 2 As shown, the heat-shrinkable sealing area 4 is provided with a stamped indentation indicator line three 401 and an indentation indicator line two 403. The indentation indicator line two 403 is provided to remind the operator that the burrs at the end of the aluminum wire should not extend beyond the indentation indicator line two 403 during welding, thus preventing the burrs at the end of the aluminum wire from being too long and affecting the sealing performance of the double-walled heat-shrinkable tubing. A sufficiently long straight area is provided between the indentation indicator line three 401 and the indentation indicator line two 403 to ensure that the overflow sealing area of ​​the double-walled heat-shrinkable tubing is sufficiently long to guarantee sealing performance.

[0030] Example 6, based on Example 5, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 and Figure 2As shown, the welding area 3 is provided with a stamped indentation indicator line 301, which is located below the second indentation indicator line 403. A groove 402 is located between the third indentation indicator line 401 and the first indentation indicator line 301. The groove 402 is provided on both sides of the area where the third indentation indicator line 401 and the first indentation indicator line 301 are located to avoid other components around the jumper terminal. The area between the second indentation indicator line 403 and the first indentation indicator line 301 is reserved for the burr at the end of the aluminum wire after welding. The second indentation indicator line 403 and the first indentation indicator line 301 together remind the operator not to allow the burr at the end of the wire to extend beyond the area between the second indentation indicator line 403 and the first indentation indicator line 301 during welding, to avoid the burr at the end of the aluminum wire being too long and affecting the sealing performance of the double-wall heat shrink tubing.

[0031] Example 7, based on any one of Examples 1 to 6, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 3 As shown, the welding area 3 is provided with a cut-resistant chamfer 303. The cut-resistant chamfer 303 is provided to prevent the aluminum wire from being cut by the edge of the terminal block after welding.

[0032] Example 8, based on Example 7, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 2 As shown, the welding area 3 is provided with a crack-resistant rounded corner 304. The crack-resistant rounded corner 304 is provided to prevent the double-walled heat shrink tubing from being punctured by the sharp edges of the grounding hole type terminal during the heat shrinking process, which would lead to the failure of the seal.

[0033] Example 9, based on Example 8, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 , Figure 3 and Figure 4 As shown, the connection area 1 and the welding area 3 are arranged perpendicularly at 90°; the connection area 1 is provided with bolt holes 101. The 90° perpendicular arrangement of the connection area 1 and the welding area 3 allows the connection area 1 to be fixed to the electrical box at a 90° angle perpendicular to the installation direction of the jumper terminal, which improves the stability of the jumper terminal installation. The bolt holes 101 on the connection area 1 facilitate bolt passage for connection. The bolt passes through the bolt hole 101 of the jumper terminal, and then the jumper terminal and the conductive sheet are pressed tightly together and the position of the jumper terminal is fixed by tightening the nut, so that the jumper terminal is connected to the circuit in the electrical box. During the tightening of the nut, under the rotational torque applied by the nut, the jumper terminal tends to rotate around the axis of the bolt hole. The jumper terminal relies on the small gap between the outline of the connection area 1 and the electrical box to prevent rotation.

[0034] Example 10, based on Example 9, provides an aluminum wire ultrasonic welding grounding hole type terminal, such as... Figure 1 , Figure 2 and Figure 3 As shown, the top of the jump-start area 2 is a clamping part 201 for the jump-start clip to hold; the clamping part 201 is wavy. The clamping part 201 is designed to clamp with the jump-start clip so that the vehicle's internal battery can be temporarily accessed from outside the vehicle. The wavy shape of the clamping part 201 is to increase the firmness of the clamping part 201 and the jump-start clip, making it less likely for the jump-start clip to slip off the clamping part 201, thus preventing the jump-start clip from slipping off the clamping part 201 and causing an unexpected power outage.

[0035] In the implementation of Example 10, the terminal with a grounding hole is formed by direct stamping and bending using sheet metal processing. The connection area 1 is located on one side of the top of the terminal body 5, and the grounding area 2 is located on the other side of the top of the terminal body 5. The connection area 1 is provided with bolt holes 101, the grounding area 2 is provided with clamping parts 201, and the welding area 3 is located at the bottom of the terminal body 5. The welding area 3 is provided with pitted dots 302.

[0036] When installing the jumper terminal of this application into the electrical box, a bolt is passed through the bolt hole 101 of the jumper terminal, and the jumper terminal and conductive sheet are pressed tightly together and the position of the jumper terminal is fixed by tightening the nut, so that the jumper terminal is connected to the circuit in the electrical box. During the tightening of the nut, under the action of the rotational torque applied by the nut, the terminal tends to rotate around the axis of the bolt hole. The jumper terminal relies on the small gap between the outline of the bolt connection area and the electrical box to prevent rotation. When temporarily drawing power from the vehicle's internal battery, the jumper clip is clamped to the clamping part 201 on the jumper area 2.

[0037] When the jumper terminal is welded to the aluminum wire, under the pressure and high-frequency mechanical vibration generated by the ultrasonic welding machine, the aluminum wire and the welding area 3 are firmly connected to form a current path. The pitted dots 302 set in the welding area 3 are beneficial for cutting and piercing the oxide film on the surface of the aluminum wire under high-frequency vibration, reducing the film resistance, increasing the cold welding area between the welding connection area and the aluminum wire, and also helping to increase the total welding contact area between the welding connection area and the wire, so as to reduce the connection resistance and increase the pull-out force of the wire. The second indentation indicator line 403 is punched on the jumper terminal. The area between the second indentation indicator line 403 and the first indentation indicator line 301 is reserved for the burr at the end of the wire after welding. The second indentation indicator line 403 and the first indentation indicator line 301 together remind the operator not to let the burr at the end of the wire exceed the area between the second indentation indicator line 403 and the first indentation indicator line 301 during welding, so as to avoid the burr being too long and affecting the heat shrink sealing performance. After the jumper terminal is welded to the aluminum wire, the overflow sealant effect of the double-wall heat shrink tubing after heating can cover and seal the entire heat shrink sealing area 4 and the welding area 3, preventing the intrusion of external moisture and other corrosive media, preventing corrosion, and ensuring the mechanical and electrical properties between the aluminum wire and the terminal welding connection area.

[0038] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An aluminum wire ultrasonic welding grounding hole type terminal, comprising a terminal body (5), characterized in that, The terminal body (5) is integrally connected to a grounding area (2), and the terminal body (5) is integrally connected to a connection area (1) for fixing the terminal and a heat shrink sealing area (4) for increasing the sealing area of ​​the double-wall heat shrink tubing overflow. The heat shrink sealing area (4) is integrally connected to a welding area (3); the welding area (3) is provided with pitted prickles (302) for increasing the welding area.

2. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 1, characterized in that: The connection area (1) and the grounding area (2) are located on the top of the terminal body (5), and the heat-shrink sealing area (4) is located at the bottom of the terminal body (5).

3. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 2, characterized in that: The terminal body (5) is a U-shaped body formed by bending sheet metal.

4. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 3, characterized in that: The heat-shrinkable sealing area (4) is provided with a groove (402).

5. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 4, characterized in that: The heat-shrinkable sealing area (4) is provided with a stamped indentation indicator line three (401) and an indentation indicator line two (403).

6. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 5, characterized in that: The welding area (3) is provided with a stamped indentation indicator line 1 (301), the indentation indicator line 1 (301) is located below the indentation indicator line 2 (403), and the groove (402) is located between the indentation indicator line 3 (401) and the indentation indicator line 1 (301).

7. The aluminum wire ultrasonic welding grounding hole type terminal according to any one of claims 1 to 6, characterized in that: The welding area (3) is provided with a cut-resistant chamfer (303).

8. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 7, characterized in that: The welding area (3) is provided with crack-resistant rounded corners (304).

9. The ultrasonic welding terminal for aluminum wire according to claim 8, characterized in that: The connecting area (1) is perpendicular to the welding area (3) at 90°; the connecting area (1) is provided with bolt holes (101).

10. The aluminum wire ultrasonic welding grounding hole type terminal according to claim 9, characterized in that: The top of the jump-start area (2) is a clamping part (201) for the jump-start clamp to clamp; the clamping part (201) is wavy.

Images