Busbar end and busbar structure

Abstract

This utility model relates to the field of battery technology and discloses a bus terminal and bus structure. By fixing a first metal component with higher rigidity to a second metal component with lower rigidity using solid-state welding, the connection is ensured to be strong while also allowing for flexible adjustment, which improves the fit and connection stability of the bus. The first metal component has a connection hole for connecting to an external power source, facilitating reliable connection to external electrical equipment and simplifying the installation process. Both the first and second metal components are coated with a third metal layer, which helps improve the overall structure's corrosion resistance and conductivity, extending the service life of the bus terminal. By rationally selecting metal materials with different rigidities and welding methods, material costs and manufacturing difficulty are effectively reduced, resulting in a structurally stable, low-cost, and widely applicable structure.

Description

Technical Field

[0001] This utility model relates to the field of battery technology, specifically to a bus terminal and bus structure. Background Technology

[0002] Busbars, widely used power connection components in power systems, are primarily used to transmit and distribute electrical energy between multiple electrical circuits. In existing technologies, common busbar materials include copper and aluminum. Copper busbars, with their excellent conductivity and stable mechanical strength, can maintain reliable electrical connections during long-term operation, making them widely used in applications requiring high electrical connection stability. However, the higher price of copper leads to higher overall manufacturing costs, hindering large-scale widespread application.

[0003] In contrast, aluminum busbars offer advantages such as light weight and low cost, making them suitable for cost-sensitive applications. However, aluminum is prone to creep under high temperatures and pressures, especially in structures where the busbar ends are bolted to external conductors. Over long-term operation, material creep can cause nuts to loosen, leading to poor contact and unstable electrical connections. These drawbacks limit the application of aluminum busbars in fields requiring high reliability. Utility Model Content

[0004] In view of this, the present invention provides a bus terminal and bus structure to solve the problems of high cost and poor connection stability of bus in the prior art.

[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows:

[0006] In a first aspect, the present invention provides a bus terminal, comprising: a first metal part and a second metal part, one end of the first metal part and one end of the second metal part being fixedly connected by solid phase welding, the rigidity of the first metal part being greater than the rigidity of the second metal part, the other end of the first metal part being provided with a connection hole for connecting to an external power source, and the second metal part being connectable to a busbar; the surfaces of the first metal part and the second metal part are coated with a third metal layer.

[0007] It has the following advantages:

[0008] This utility model provides a bus terminal that fixes a more rigid first metal component to a less rigid second metal component using solid-state welding. This ensures a strong connection while also allowing for structural flexibility, improving the bus's fit and connection stability. The first metal component has a connection hole for connecting to an external power source, facilitating reliable connection to external electrical equipment and simplifying the installation process. Both the first and second metal components are coated with a third metal layer, which enhances the overall structure's corrosion resistance and conductivity, extending the bus terminal's service life. By rationally selecting metal materials with different rigidities and welding methods, material costs and manufacturing difficulty are effectively reduced. The overall structure is highly stable, low-cost, and widely applicable, better meeting the high-performance, low-cost requirements of existing power systems for bus terminals.

[0009] According to a first aspect of the present invention, the first metal part is provided in a stepped structure, and the second metal part is a straight section or a stepped structure.

[0010] According to a first aspect of the present invention, the first metal part is made of copper, the second metal part is made of aluminum, and the third metal layer is made of nickel or tin.

[0011] According to a first aspect of the present invention, the first metal part and the second metal part are fixed by extrusion welding.

[0012] Secondly, this utility model also provides a busbar structure, including: a busbar and a busbar end; the end of a second metal member away from the first metal member is fixedly connected to the busbar, and the metal material of the busbar is the same as that of the second metal member.

[0013] According to a second aspect of the present invention, the busbar structure further includes a protective sleeve, the busbar is inserted through the protective sleeve, both ends of the busbar are exposed to form a connecting end, and the second metal member is fixedly connected to the connecting end.

[0014] According to a second aspect of the present invention, the bus terminal and the second metal part are fixed by laser welding.

[0015] According to a second aspect of the present invention, the busbar has multiple bending structures.

[0016] According to a second aspect of the present invention, the protective sleeve is made of insulating material. Attached Figure Description

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

[0018] Figure 1 This is a schematic diagram of the structure of a busbar terminal provided in the first aspect embodiment of the present invention;

[0019] Figure 2 This is a partial structural diagram of a busbar structure provided in the second aspect embodiment of the present utility model.

[0020] Explanation of reference numerals in the attached figures:

[0021] 1. Busbar end; 11. First metal part; 12. Second metal part; 111. Connecting hole; 2. Busbar; 3. Protective sleeve. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0023] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," 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 do not 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. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0025] Furthermore, the technical features involved in the different embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.

[0026] Reference Figure 1 As shown, in a first aspect of this utility model, a bus terminal 1 is provided, comprising: a first metal part 11 and a second metal part 12, one end of the first metal part 11 and one end of the second metal part 12 are fixedly connected by solid phase welding, the rigidity of the first metal part 11 is greater than the rigidity of the second metal part 12, the other end of the first metal part 11 is provided with a connection hole 111 for connecting to an external power source, and the second metal part 12 can be connected to a busbar 2; the surfaces of the first metal part 11 and the second metal part 12 are coated with a third metal layer.

[0027] Specifically, this utility model provides a bus terminal 1, which is fixedly connected by solid-state welding of a first metal part 11 with higher rigidity and a second metal part 12 with lower rigidity. This ensures a strong connection while also allowing for structural flexibility, improving the bus's fit and connection stability. The first metal part 11 has a connection hole 111 for connecting to an external power source, facilitating reliable connection to external electrical equipment and simplifying the installation process. Both the first metal part 11 and the second metal part 12 are coated with a third metal layer, which helps improve the overall structure's corrosion resistance and conductivity, extending the service life of the bus terminal 1. By rationally selecting metal materials with different rigidities and welding methods, material costs and manufacturing difficulties are effectively reduced. The overall structure is highly stable, low-cost, and widely applicable, better meeting the high-performance, low-cost requirements of existing power systems for busbars.

[0028] In a first aspect of the present invention, the first metal part 11 is provided in a stepped structure, and the second metal part 12 is a straight section or a stepped structure.

[0029] Specifically, the first metal component 11 is designed with a stepped structure, while the second metal component 12 is either a straight section or a stepped structure. This structural design allows for a high degree of spatial alignment of the busbar end 1, effectively improving the connection accuracy with external power supplies or electrical devices during installation. The stepped structure facilitates the limiting and guiding functions of the connection points, preventing misalignment during installation and improving assembly efficiency and reliability. Simultaneously, if the second metal component 12 adopts a straight section structure, it allows for a thorough fit with planar conductors such as the busbar 2 and the housing, thereby improving electrical connection performance. This structural combination design not only helps improve overall connection stability but also considers the mechanical strength and electrical performance of the end structure, providing structural assurance for the long-term reliable operation of the busbar system.

[0030] In the first aspect of this utility model, the first metal part 11 is made of copper, the second metal part 12 is made of aluminum, and the third metal layer is made of nickel or tin.

[0031] Specifically, the first metal component 11 is made of copper, the second metal component 12 is made of aluminum, and the third metal layer is made of nickel or tin. This combination of copper and aluminum achieves a reasonable balance between strength and flexibility in the bus terminal 1, while also considering conductivity and cost control. Copper, with its excellent conductivity and mechanical strength, serves as the rigid first metal component 11, which helps improve the electrical performance and structural stability of the connection between the terminal and the external power source. Aluminum, with its low density and cost, serves as the flexible second metal component 12, effectively reducing overall weight and material costs, while also facilitating processing and forming.

[0032] Understandably, a third metal layer, made of nickel or tin, is applied to the surface of copper and aluminum components. This provides excellent oxidation and corrosion resistance, improving the long-term stability and service life of the overall structure. The nickel or tin layer also offers good solderability and conductivity, contributing to consistent subsequent welding processes and reliable electrical connections.

[0033] In a first aspect of the present invention, the first metal part 11 and the second metal part 12 are fixed by solid phase welding.

[0034] Specifically, the first metal component 11 and the second metal component 12 are fixed together by solid-state welding. Compared with traditional hot welding methods such as fusion welding and brazing, solid-state welding can achieve high-strength connections between dissimilar metals at lower temperatures, avoiding the performance degradation of the weld layer caused by an excessively large heat-affected zone. During the connection process, a certain pressure is applied, causing plastic deformation of the contact surfaces and atomic diffusion to form a non-brittle metallurgical bond, thereby achieving strong mechanical bonding and low contact resistance.

[0035] Solid-state welding eliminates the need for additional welding materials or flux, simplifying the production process, improving welding efficiency, and reducing defects such as incomplete welds and cracks at the joint, thus enhancing product consistency and reliability. This connection method is particularly suitable for joining dissimilar metals like copper and aluminum, ensuring joint strength while effectively suppressing the risk of electrochemical corrosion at the contact interface. The solid-state welding process not only improves the structural stability and electrical performance of bus terminal 1 but also offers advantages such as simple process, low cost, and strong adaptability, making it suitable for large-scale production applications.

[0036] Understandably, during solid-state welding, the connecting surfaces of the first metal part 11 and the second metal part 12 can be cleaned, and the welding process can be repeated multiple times in a welding machine. The principle of copper-aluminum solid-state welding is as follows: under strong pressure, at least 2000 MPa, intense plastic deformation is caused at the copper-aluminum connection surface, which breaks down and extrudes the oxide film on the contact surface. The two metals then create new metal surfaces that come into contact with each other, and their atoms reach a distance that attracts each other, allowing the atoms to diffuse and form a solid bond. Subsequently, the burrs and rough edges generated during the pressing process are removed, and a third metal layer is plated on the welded end surface.

[0037] Reference Figure 2 As shown, in a second aspect of this utility model, this utility model also provides a busbar structure, including: a busbar 2 and a busbar end 1; the end of the second metal part 12 away from the first metal part 11 is fixedly connected to the busbar 2, and the metal material of the busbar 2 is the same as that of the second metal part 12.

[0038] Specifically, the present invention provides a busbar structure that combines the busbar 2 with the busbar end 1, so that the end of the second metal part 12 away from the first metal part 11 is fixedly connected to the busbar 2. The metal material of the busbar 2 is the same as that of the second metal part 12. From the perspective of structural compatibility and electrical connection, the conductivity consistency and thermal expansion matching of the connection area are significantly improved.

[0039] Since the second metal component 12 and the busbar 2 are both made of aluminum, electrochemical corrosion problems caused by direct connection of dissimilar metals can be effectively avoided, improving the corrosion resistance and long-term stability of the overall structure. At the same time, material matching can reduce thermal stress caused by differences in thermal expansion coefficients, reduce the risk of cracking or loosening at the connection points under temperature changes, and extend the service life of the structure.

[0040] This structure creates a high-strength integrated connection between busbar end 1 and busbar 2, which reduces the weight of the busbar structure and lowers the cost, making it particularly suitable for new energy vehicle battery systems.

[0041] In a second aspect embodiment of the present invention, the busbar structure further includes a protective sleeve 3, a busbar 2 passing through the protective sleeve 3, and both ends of the busbar 2 being exposed to form a connecting end, and a second metal part 12 being fixedly connected to the connecting end.

[0042] Specifically, busbar 2 is installed through protective sleeve 3, with both ends of busbar 2 exposed to form connection ends, and the second metal part 12 is fixedly connected to the connection ends. By setting protective sleeve 3, effective insulation and mechanical protection can be provided for the main body of busbar 2, avoiding problems such as bending, scratching or short circuit caused by external forces during transportation, installation or operation, and significantly improving the safety and durability of the busbar system.

[0043] The exposed ends of busbar 2 form connection terminals, ensuring that while protected, it retains necessary electrical connection areas. This facilitates efficient and reliable mechanical and electrical connection with the second metal component 12, guaranteeing that the overall conductivity is unaffected by the protective structure. This structure also allows for modular deployment based on standardized packaging, improving product versatility and ease of installation.

[0044] The protective sleeve 3 can be made of materials with good insulation, high temperature resistance, and chemical corrosion resistance (such as heat shrink tubing or insulating plastic shell) to further enhance the operational stability of the bus system in complex working environments. This design takes into account structural safety, electrical performance, and industrial practicality, and is especially suitable for power distribution systems or new energy transmission systems in high-voltage or harsh environments.

[0045] According to a second aspect of the present invention, the bus terminal 1 and the second metal part 12 are fixed by laser welding.

[0046] Specifically, the bus terminal 1 and the second metal part 12 are fixed by laser welding. Compared with traditional resistance welding and brazing, laser welding has significant advantages such as high energy density, low heat input, narrow weld seam, and fast welding speed. Laser welding can achieve a high-precision and high-strength connection between the bus terminal 1 and the second metal part 12, ensuring that the connection has good mechanical and electrical properties.

[0047] Because laser welding is a non-contact heat source processing method, it can significantly reduce the heat-affected zone on the surface of the joined parts, lowering residual stress and the risk of deformation, making it particularly suitable for joining dissimilar metals such as copper and aluminum. This process offers high precision and a high degree of automation, which helps improve product consistency and mass production efficiency.

[0048] Meanwhile, the weld seam formed by laser welding is dense with few pores and has high connection strength, which can effectively improve the operational reliability of the busbar structure under complex working conditions such as high temperature and high current.

[0049] In a second aspect embodiment of this utility model, the busbar 2 has multiple bending structures.

[0050] Specifically, busbar 2 features multiple bends, a design that allows for flexible adjustment of the cabling path based on available installation space, effectively adapting to the spatial requirements of different electrical devices. These bends enhance the busbar's deployability and adaptability in complex environments, making it particularly suitable for cabinet cabling, vehicle electrical systems, or other space-constrained scenarios.

[0051] Furthermore, pre-setting the bending position can buffer mechanical stress, reducing the risk of structural damage caused by thermal expansion and contraction or external impacts, and improving the mechanical stability and fatigue life of the busbar system. The bending structure can also, to some extent, serve as a limiting and self-positioning function, facilitating standardized assembly and improving production efficiency.

[0052] In a second aspect of this utility model, the protective sleeve 3 is made of insulating material.

[0053] Specifically, the protective sleeve 3 is made of insulating material, and different material selections can provide various functional protections according to specific application scenarios. For example, plastic materials have good moldability and insulation properties, making them suitable for standard electrical protection in general environments; rubber materials have strong flexibility and good impact resistance, making them suitable for structural buffering and protection in vibration environments; silicone materials have excellent properties such as high temperature resistance, aging resistance, and corrosion resistance, making them suitable for long-term use in high-temperature or harsh working conditions.

[0054] These protective materials all possess excellent electrical insulation properties, effectively preventing short circuits or electric shocks caused by contact between busbar 2 and external conductive objects, significantly improving the safety of the busbar structure. Simultaneously, these materials also exhibit good weather resistance and sealing properties, providing comprehensive environmental protection for busbar 2 and extending the system's service life.

[0055] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A bus terminal, characterized in that, include: The first metal part (11) and the second metal part (12) are fixedly connected at one end of the first metal part (11) and at one end of the second metal part (12) by solid phase welding. The rigidity of the first metal part (11) is greater than that of the second metal part (12). The other end of the first metal part (11) is provided with a connection hole (111) for connecting to an external power source. The second metal part (12) can be connected to the busbar (2). The surfaces of the first metal part (11) and the second metal part (12) are coated with a third metal layer.

2. The bus terminal according to claim 1, characterized in that, The first metal part (11) is arranged in a stepped structure, and the second metal part (12) is a straight section or a stepped structure.

3. The bus terminal according to claim 1, characterized in that, The first metal part (11) is made of copper, the second metal part (12) is made of aluminum, and the third metal layer is made of nickel or tin.

4. The bus terminal according to any one of claims 1-3, characterized in that, The first metal part (11) and the second metal part (12) are fixed by solid phase welding.

5. A busbar structure, characterized in that, include: Busbar (2), wherein the busbar (2) is made of metal; The bus terminal (1) according to any one of claims 1-4, wherein the end of the second metal part (12) away from the first metal part (11) is fixedly connected to the busbar (2), and the metal material of the busbar (2) is the same as that of the second metal part (12).

6. The busbar structure according to claim 5, characterized in that, It also includes a protective sleeve (3), the busbar (2) is inserted through the protective sleeve (3), the two ends of the busbar (2) are exposed to form a connecting end, and the second metal part (12) is fixedly connected to the connecting end.

7. The busbar structure according to claim 5, characterized in that, The bus terminal (1) and the second metal part (12) are fixed by laser welding.

8. The busbar structure according to claim 5, characterized in that, The busbar (2) has multiple bending structures.

9. The bus structure according to claim 6, characterized in that, The protective sleeve (3) is made of insulating material.

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