High-precision flux-cored aluminum welding ring for welding of water-cooled plates of new energy vehicles

Abstract

The utility model discloses a high-precision flux-cored aluminum welding ring for new energy automobile water cooling plate welding relates to welding material technical field. The high-precision flux-cored aluminum welding ring for new energy automobile water cooling plate welding, through the interference fit of aluminum base alloy positioning boss and water cooling plate positioning groove, can realize high-precision positioning without jig, and the boss is consistent with the base material quality of welding ring, avoids the corrosion risk from the root; At the same time, the 45 degree guide inclined body design guides the quick sleeve of welding ring into the pipe orifice, and the single-station assembly time is shortened, and the traditional assembly efficiency is greatly improved, and the beat demand of perfect adaptation new energy automobile mass production scene is required, through the double annular partition flux core cavity, the outer ring high flux core core removes the edge oxide film preferentially, the inner ring high flux core core strengthens the center strength, and the cooperation U type cross section design makes the flux core release efficiency improve, effectively avoids the inclusion defect, and the annular reinforcing rib forms the stepped weld after melting, increases the contact area, and improves the fatigue strength.

Description

Technical Field

[0001] This utility model relates to the field of welding materials technology, and in particular to a high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles. Background Technology

[0002] As a core component of the battery thermal management system, the welding quality of the water-cooled plate in new energy vehicles directly determines the sealing performance and structural reliability of the coolant circulation, thereby affecting the heat dissipation efficiency of the battery pack and the safety of the entire vehicle. The flux-cored aluminum welding ring, as a key welding material for connecting the water-cooled plate to the pipe, achieves metallurgical bonding through the melting of the built-in brazing filler metal, while relying on the flux in the core to remove the dense oxide film on the aluminum surface, which is the core carrier to ensure welding strength and sealing performance.

[0003] Currently, most flux-cored aluminum welding rings widely used in the industry adopt a single annular flux-cored cavity structure, with the flux filling the cavity evenly. Although this design can meet basic welding requirements, it has a significant mismatch between function and requirements: During the welding of water-cooled plates, the weld edge is the area where the aluminum substrate oxide film is most concentrated. Sufficient flux must be spread first to completely remove the oxide film. Otherwise, the oxide film residue can easily lead to defects such as edge incomplete fusion and porosity, directly affecting the sealing performance. Meanwhile, the weld center is the core stress area, which needs sufficient filler metal to ensure the mechanical strength of the joint. If the filler metal is insufficient, it will lead to strength reduction and make it difficult to withstand the vibration and impact during vehicle operation.

[0004] Increasing the flux ratio based on edge requirements leads to insufficient filler metal in the center, resulting in decreased joint tensile strength. Conversely, increasing the filler metal ratio based on center requirements results in insufficient flux at the edges, incomplete oxide film removal, and a high weld leakage rate. Furthermore, traditional annular flux-cored cavities are mostly closed circular cross-sections, with long flux release paths and low efficiency, further exacerbating the imbalance in material distribution between the edges and the center. This leads to large fluctuations in weld quality, making it difficult to meet the stringent requirements of new energy vehicles for high sealing, high strength, and long lifespan of water-cooled plates. Therefore, optimizing the flux distribution structure to meet the regionalized needs of water-cooled plate welding has become a key breakthrough for improving welding reliability. Utility Model Content

[0005] The purpose of this invention is to at least solve one of the technical problems existing in the prior art, and to provide a high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles, which can solve the above problems.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles, comprising an inner portion of an aluminum base material, an inner ring flux storage layer fixedly connected to the outer portion of the inner portion of the aluminum base material, an inner and outer flux connection body fixedly connected to the outer portion of the inner ring flux storage layer, an outer ring flux storage layer fixedly connected to the outer portion of the inner and outer flux connection body, an outer portion of the aluminum base material fixedly connected to the outer portion of the outer ring flux storage layer, and a protective coating disposed on the outer portion of the aluminum base material; A water-cooled plate is installed under the protective coating. Three positioning grooves are opened on the water-cooled plate, and a water-cooled pipe opening is provided on the water-cooled plate. The flux-cored aluminum welding ring is completely fitted onto the water-cooled pipe opening.

[0007] Preferably, the protective coating is fixedly connected to three annular reinforcing ribs, and after welding, the annular reinforcing ribs melt and form a stepped weld with the water-cooled plate shell.

[0008] Preferably, two guide vanes are fixedly connected to the inner side of the protective coating.

[0009] Preferably, the bottom of the protective coating is fixedly connected with three positioning bosses, which are used to interference fit with three positioning grooves opened on the water-cooling plate, and the positioning bosses are adapted to the water-cooling pipe openings on the water-cooling plate.

[0010] Preferably, the outer ring flux storage layer accounts for 60% of the total flux capacity and is filled with flux with a high flux content, while the inner ring flux storage layer accounts for 40% of the total flux capacity and is filled with flux with a high solder content.

[0011] Preferably, the overall cross-sectional shape of the core cavity formed by the inner core storage layer, the inner and outer core connectors, and the outer core storage layer is U-shaped with the opening facing the welding contact surface.

[0012] Preferably, the material of the positioning boss is the same as that of the inner part and the outer part of the aluminum base material.

[0013] Compared with the prior art, the beneficial effects of this utility model are: 1. This high-precision flux-cored aluminum welding ring, used for welding water-cooled plates in new energy vehicles, features a double-ring partitioned flux-cored cavity. The outer ring, with its high flux core, prioritizes removing the edge oxide film, while the inner ring, with its high brazing filler metal core, strengthens the center. Combined with a U-shaped cross-section design, this improves flux release efficiency and effectively avoids inclusion defects. The stepped weld formed after the ring reinforcing ribs melt increases the contact area and enhances fatigue resistance. Furthermore, the protective coating provides corrosion protection, and the weld is sealed and leak-free under pressure, comprehensively ensuring the long-term stable operation of the water-cooled plate under complex conditions such as vibration and high / low temperature cycling, significantly extending its service life.

[0014] 2. This high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles achieves high-precision positioning without the need for fixtures through the interference fit between the aluminum-based alloy positioning boss and the positioning groove of the water-cooled plate. Moreover, the boss and the welding ring base material are the same, which avoids the risk of corrosion from the source. At the same time, the 45° guide angle design guides the welding ring to be quickly fitted into the pipe opening, shortening the assembly time per station and greatly improving the efficiency compared with traditional assembly, perfectly adapting to the cycle time requirements of mass production scenarios for new energy vehicles. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is an isometric schematic diagram of the high-precision flux-cored aluminum welding ring used for welding water-cooled plates in new energy vehicles according to this utility model; Figure 2 This is a schematic cross-sectional view of the high-precision flux-cored aluminum welding ring used for welding water-cooled plates in new energy vehicles according to this utility model. Figure 3 This is a top view schematic diagram of the high-precision flux-cored aluminum welding ring used for welding water-cooled plates in new energy vehicles according to this utility model; Figure 4 This is a front view schematic diagram of the high-precision flux-cored aluminum welding ring used for welding water-cooled plates in new energy vehicles according to this utility model.

[0016] Reference numerals: 1. Water-cooled plate; 2. Positioning groove; 3. Water-cooled pipe inlet; 4. Inner part of aluminum base material; 5. Inner ring core storage layer; 6. Inner and outer core connector; 7. Outer ring core storage layer; 8. Outer part of aluminum base material; 9. Protective coating; 10. Positioning boss; 11. Annular reinforcing rib; 12. Guide slant. Detailed Implementation

[0017] This section will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but they should not be construed as limiting the scope of protection of the present utility model.

[0018] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional or positional relationship shown in the accompanying drawings. They 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. Therefore, they should not be construed as limitations on this utility model.

[0019] In the description of this utility model, terms such as greater than, less than, and exceeding are understood to exclude the stated number, while terms such as above, below, and within are understood to include the stated number. The use of terms like "first" and "second" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the quantity or sequence of the indicated technical features.

[0020] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0021] Please see Figure 1-4 This utility model provides a technical solution: a high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles, comprising an inner part 4 of an aluminum base material, an inner ring flux storage layer 5 fixedly connected to the outer side of the inner part 4 of the aluminum base material, an inner and outer flux connection body 6 fixedly connected to the outer side of the inner ring flux storage layer 5, an outer ring flux storage layer 7 fixedly connected to the outer side of the inner and outer flux connection body 6, an outer part 8 of an aluminum base material fixedly connected to the outer ring flux storage layer 7, and a protective coating 9 provided on the outer part 8 of the aluminum base material; The overall cross-section of the flux core cavity is U-shaped with the opening facing the welding contact surface. Compared with the traditional circular flux core cavity, this structure increases the contact area between the flux core and the welding area, improves the flux core release efficiency, effectively avoids weld inclusion defects caused by flux residue or flux core accumulation, and ensures that the weld formation is uniform and dense. The protective coating 9 is fixedly connected to three annular reinforcing ribs 11 on its outer periphery, and to two guide slant bodies 12 on its inner side. The inclined plane of guide body 12 has an inclination angle of 45°; The bottom of the protective coating 9 is fixedly connected to three positioning bosses 10. A water-cooling plate 1 is provided under the positioning bosses 10. Three positioning grooves 2 are opened on the water-cooling plate 1. A water-cooling pipe port 3 is fixedly connected to the water-cooling plate 1. The 45° inclined structure of the guide body 12 can quickly fit the edge of the water-cooled pipe opening 3. Even if there are small burrs at the pipe opening, the inclined guide can prevent jamming and guide the welding ring to be smoothly inserted into the target position. During the insertion of the welding ring, the three positioning bosses 10 fixedly connected to the bottom of the outer part 8 of the aluminum base material are precisely aligned with the three positioning grooves 2 preset on the water-cooled plate 1, forming an interference fit.

[0022] Working principle: In the initial stage of assembly, the operator aligns the welding ring with the water-cooling pipe opening 3 on the water-cooling plate 1. The two guide angles 12 on the inner side of the outer part 8 of the aluminum base material of the welding ring play a guiding role. The 45° inclined structure can quickly fit the edge of the water-cooling pipe opening 3. Even if there are small burrs on the pipe opening, the inclined guide can avoid jamming and guide the welding ring to smoothly fit into the target position, shortening the assembly time of a single station to less than 30 seconds, which is suitable for mass production needs. During the fitting process, the three positioning bosses 10 fixedly connected to the bottom of the outer part 8 of the aluminum base material are precisely aligned with the three positioning grooves 2 preset on the water-cooling plate 1, forming an interference fit. Since the height and width tolerance of the positioning bosses 10 are strictly controlled and the material is the same as that of the aluminum base material, which is aluminum base alloy, it avoids electrochemical corrosion caused by contact between different materials. Through the interlocking structure of the bosses and grooves, the welding ring can be accurately positioned without additional tooling fixtures, ensuring the coaxiality of the welding ring and the water-cooling pipe opening 3 and the uniformity of the welding gap.

[0023] After welding begins, the aluminum alloy brazing filler metal melts upon heating. The double-ring partitioned flux-cored cavity structure of the welding ring plays a layered role: the high flux content filler metal in the outer ring flux storage layer 7 melts preferentially, and the melted flux quickly covers the welding edge area, thoroughly removing the oxide film on the aluminum surface of the water-cooled plate 1 and water-cooled pipe 3, providing a clean metallurgical bonding environment for weld formation and ensuring the sealing of the weld edge; the high flux content filler metal in the inner ring flux storage layer 5 then melts fully, providing sufficient filler metal to fill the welding gap and strengthening the mechanical strength of the weld center area; at the same time, the flux-cored cavities are fixedly connected by the inner and outer flux-cored connectors 6, and the overall cross-section is U-shaped with the opening facing the welding contact surface, compared with the traditional circular flux-cored core. The cavity structure increases the contact area between the flux core and the welding area, improving the flux core release efficiency and effectively avoiding weld inclusion defects caused by flux residue or flux core accumulation, ensuring uniform and dense weld formation. During welding, the protective coating 9 on the outer part 8 of the aluminum base material can block welding spatter from damaging the weld ring substrate, while preventing the substrate from being oxidized in the high-temperature welding environment, thus protecting the integrity of the weld ring structure. The three annular reinforcing ribs 11 fixedly connected to the outer periphery of the protective coating 9 melt when heated, and fuse with the water-cooled plate 1 shell and the weld to form a stepped weld, increasing the contact area between the weld and the water-cooled plate 1, significantly enhancing the fatigue strength of the joint, and meeting the service life requirements of more than 100,000 kilometers for new energy vehicles.

[0024] After welding, the interference fit structure between the positioning boss 10 and the positioning groove 2 is further stabilized as the weld solidifies. Combined with the dense weld formed by the layered flux core, the joint seal meets the requirements of leak-free airtightness test. The protective coating 9 continues to play a role in corrosion prevention and wear resistance, improving the salt spray and damp heat resistance of the weld ring and weld area, and avoiding corrosion failure during long-term service. The inner part 4 and the outer part 8 of the aluminum base material form a complete structural support through the inner and outer flux core connectors 6, ensuring the overall mechanical stability of the weld ring and ensuring long-term stable operation of the weld under complex working conditions such as vibration and high and low temperature cycles during the operation of new energy vehicles, thus comprehensively improving the reliability and service life of the water-cooled plate 1 welding.

[0025] Structural Description: The inner part 4 of the aluminum base material is the basic support structure inside the welding ring. The inner ring flux core storage layer 5 is fixedly connected to the outside of the inner part 8 of the aluminum base material through the inner and outer flux core connectors 6 to form a complete aluminum base frame. As the core support inside, it provides a stable mounting carrier for the inner ring flux core storage layer 5, ensuring that the position of the inner ring flux core is fixed during the welding process and avoiding the displacement of flux core distribution due to structural deformation. Together with the outer part 8, it forms a rigid frame to ensure the overall shape stability of the welding ring and to meet the precision assembly requirements of the water-cooled plate 1 nozzle. Inner ring flux core storage layer 5: Located on the outer side of the inner part 4 of the aluminum base material, it is connected to the outer ring flux core storage layer 7 through the inner and outer flux core connectors 6. It is filled with flux core with high solder content, and together with the outer ring flux core storage layer 7, it forms a double-ring partitioned flux core cavity. It specifically meets the mechanical strength requirements of the weld center. The high proportion of solder melts fully during welding, providing sufficient filling for the central area, avoiding the strength reduction problem caused by insufficient solder in the center in the traditional uniform flux core structure, and significantly improving the tensile strength of the joint. Inner and outer core connector 6: This intermediate structure connects the inner core storage layer 5 and the outer core storage layer 7, enabling the dual cavities to form a stable integrated core system. It also works in conjunction with the inner part 4 and the outer part 8 of the aluminum base material to form a U-shaped cross-sectional profile. This ensures that the relative positions of the inner and outer core storage layers are fixed, preventing deformation or displacement of the core cavity before welding. At the same time, as a supporting structure for the U-shaped cross-section, it ensures that the opening of the core cavity faces the welding contact surface, providing a stable channel for efficient core release. Outer ring flux storage layer 7: Located outside the inner and outer flux connector 6, it is externally fixed to the outer part 8 of the aluminum base material and internally filled with flux with high flux content, forming a functional partition with the inner ring flux storage layer 5; it prioritizes meeting the oxide film removal requirements of the weld edge, and the high proportion of flux melts first during welding and covers the edge area, completely breaking the oxide film on the aluminum surface, avoiding sealing defects such as incomplete fusion and porosity caused by insufficient flux at the edge in traditional structures, and ensuring the sealing of the weld edge; The outer part 8 of the aluminum base material is the basic support structure on the outside of the welding ring. It is internally fixedly connected to the outer ring core storage layer 7 and externally provided with a protective coating 9. The bottom is connected to the positioning boss 10, forming a symmetrical aluminum base frame with the inner part 4 of the aluminum base material. As the outer core support, it protects the outer ring core storage layer 7 from external mechanical damage. Together with the inner part 4, it forms a complete aluminum base shell, ensuring the structural stability of the core cavity during transportation and assembly. At the same time, it provides an installation foundation for functional structures such as the protective coating 9 and the annular reinforcing rib 11. Protective coating 9: Covers the outer surface 8 of the aluminum substrate, with annular reinforcing ribs 11 fixedly connected to the periphery, guide slant bodies 12 fixedly connected to the inner side, and the bottom connected to the positioning boss 10. The material is a silane-ceramic composite passivation film or DLC lubrication coating. During welding, it prevents spatter from damaging the aluminum substrate and avoids substrate oxidation under high temperature conditions. During long-term service, it plays a role in corrosion prevention and wear resistance, improves the salt spray and damp heat resistance of the weld ring and weld area, and reduces the risk of corrosion failure. At the same time, it provides a stable adhesion base for the annular reinforcing ribs 11, guide slant bodies 12, and positioning boss 10. Circular reinforcing ribs 11: There are 3 in total, distributed axially along the outer periphery of the protective coating 9, and integrally formed with the welding ring substrate; they melt when heated during welding and fuse with the water-cooled plate 1 shell and the weld to form a stepped weld, which increases the contact area between the weld and the water-cooled plate 1 by more than 30%; by increasing the stress area, the fatigue strength of the joint is significantly enhanced, meeting the service life requirements of more than 100,000 kilometers for new energy vehicles. Guide slant 12: There are 2 in total, located inside the protective coating 9, with a 45° slant, symmetrically distributed along the welding ring axis; during assembly, the slant structure quickly fits the edge of the water-cooled pipe opening 3, and even if there are small burrs on the pipe opening, it can guide the welding ring to be smoothly inserted and avoid jamming; the assembly time of a single station is shortened to less than 30 seconds, which greatly improves the efficiency of mass production and meets the production cycle requirements of new energy vehicles; Positioning bosses 10: There are 3 in total, fixed to the bottom of the protective coating 9, forming an interference fit with the positioning grooves 2 on the water-cooling plate 1, and the material is the same as the aluminum base material; through the interlocking structure of the bosses and grooves, high-precision positioning of ≤0.05mm can be achieved without additional tooling fixtures, ensuring the coaxiality of the welding ring and the water-cooling pipe opening 3 and the uniformity of the welding gap; the aluminum base alloy material avoids electrochemical corrosion caused by contact between dissimilar metals and improves long-term service stability; Positioning grooves 2 on water-cooled plate 1: There are 3 grooves on the surface of water-cooled plate 1, and their size matches that of positioning boss 10. They are used to form an interference fit with the boss. They serve as positioning references and precisely engage with the boss to provide a stable assembly positioning point for the welding ring. This ensures that the relative position of the welding ring and water-cooled plate 1 is fixed before welding, thus ensuring consistent welding quality from the assembly source. Water-cooled pipe port 3: Fixed on the water-cooled plate 1, it is the target position for the welding ring to be inserted and is the core connection interface for welding the water-cooled plate 1 and the welding ring. As a key part of the welding contact, it is precisely matched with the positioning boss, flux core cavity and other structures of the welding ring to ensure uniform heat distribution and proper flux core filling during welding, and finally form a dense sealing weld to ensure the reliability of coolant circulation.

[0026] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model.

Claims

1. A high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles, comprising an inner portion (4) of an aluminum-based substrate, characterized in that: An inner ring drug core storage layer (5) is fixedly connected to the inner part (4) of the aluminum base material. An inner and outer drug core connector (6) is fixedly connected to the outer part of the inner ring drug core storage layer (5). An outer ring drug core storage layer (7) is fixedly connected to the outer part of the inner and outer drug core connector (6). An outer part (8) of the aluminum base material is fixedly connected to the outer part of the outer ring drug core storage layer (7). A protective coating (9) is provided on the outer part (8) of the aluminum base material. A water-cooled plate (1) is provided under the protective coating (9). Three positioning grooves (2) are provided on the water-cooled plate (1). A water-cooled pipe opening (3) is provided on the water-cooled plate (1). The flux-cored aluminum welding ring is fitted onto the water-cooled pipe opening (3).

2. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 1, characterized in that: The protective coating (9) is fixedly connected to three annular reinforcing ribs (11). After welding, the annular reinforcing ribs (11) melt and form a stepped weld with the water-cooled plate (1) shell.

3. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 2, characterized in that: Two guide bodies (12) are fixedly connected to the inner side of the protective coating (9).

4. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 3, characterized in that: The protective coating (9) has three positioning bosses (10) fixedly connected to its bottom. The positioning bosses (10) are used to make an interference fit with the three positioning grooves (2) opened on the water-cooled plate (1).

5. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 4, characterized in that: The outer ring core storage layer (7) accounts for 60% of the total core capacity and is filled with cores containing high flux content. The inner ring core storage layer (5) accounts for 40% of the total core capacity and is filled with cores containing high solder content.

6. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 5, characterized in that: The overall cross-sectional shape of the core cavity, which is formed by the inner core storage layer (5), the inner and outer core connectors (6), and the outer core storage layer (7), is U-shaped with the opening facing the welding contact surface.

7. The high-precision flux-cored aluminum welding ring for welding water-cooled plates in new energy vehicles according to claim 6, characterized in that: The material of the positioning boss (10) is the same as that of the inner part (4) and the outer part (8) of the aluminum base material.

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