Conductive bar, conductive bar assembly, and vehicle electrical device system

Abstract

Conductive bar, conductive bar assembly, and vehicle electrical device system. The conductive bar is configured to be electrically connected between two electrical devices, and the conductive bar includes at least one connection section. The elastic modulus of the connection section is E, the width of the connection section is ω, the thickness of the connection section is δ, and the thickness δ of the connection section satisfies 【Equation 1】 JPEG2025522579000024.jpg12168, where λ = 0.085 Gpa / mm, the units of both ω and δ are mm, the unit of E is Gpa, and E is in the range of 55 Gpa to 120 Gpa.

Description

Technical Field

[0001] Cross - Reference to Related Applications This disclosure claims the priority and benefit of Chinese Patent Application No. 202210760496.7, filed on June 30, 2022, entitled "CONDUCTIVE BAR, CONDUCTIVE BAR ASSEMBLY, AND VEHICLE ELECTRICAL DEVICE SYSTEM". The entire content of the above application is incorporated herein by reference.

[0002] This disclosure relates to the field of conductive bar technology, and more particularly, to conductive bars, conductive bar assemblies, and vehicle electrical device systems.

Background Art

[0003] Electrical devices on vehicles are usually connected by conductive bars. During the movement of the vehicle under road conditions that cause long - term vibrations, stress concentration occurs in the conductive bars during long - term use, which may lead to the breakage of the conductive bars due to the vibrations during operation. As a result, the conductive bar assemblies of the vehicle do not last long, and the vehicle cannot achieve a long total driving distance under actual road conditions.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The object of this disclosure is to provide a conductive bar, a conductive bar assembly, and a vehicle electrical device system. The conductive bar can avoid the breakage of the conductive bar due to vibrations during operation, and by solving the problem of stress concentration in the conductive bar during long - term use, ensure that the conductive bar assembly manufactured and formed by using the conductive bar is reliable and long - lasting, and that the vehicle can achieve a long total driving distance under road conditions that cause long - term vibrations.

Means for Solving the Problems

[0005] The present disclosure provides a conductive bar configured to be electrically connected between two electrical devices. The conductive bar includes at least one connection section. The elastic modulus of the connection section is E. The width of the connection section is ω. The thickness of the connection section is δ. The thickness δ of the connection section satisfies [Number] . λ = 0.085 Gpa / mm. The units of both ω and δ are mm. The unit of E is Gpa. E is in the range of 55 Gpa to 120 Gpa.

[0006] In some embodiments, the thickness δ of the connection section is [Number] , [Number] , [Number] , [Number] , or [Number] .

[0007] In some embodiments, a plurality of connection sections are provided. The plurality of connection sections include a first connection section, a second connection section, and a third connection section. The second connection section and the third connection section are respectively disposed at two opposite ends of the first connection section and are respectively configured to be electrically connected to two electrical devices.

[0008] In some embodiments, the extending direction of the first connection section is parallel to the first direction, the extending directions of the second connection section and the third connection section are both parallel to the second direction, and the first direction is perpendicular to the second direction.

[0009] In some embodiments, the conductive bar has a planar plate shape, and the second direction is perpendicular to the thickness direction of the first connection section.

[0010] In some embodiments, the conductive bar has a three-dimensional structure, and the second direction is parallel to the thickness direction of the first connection section.

[0011] In some embodiments, the plurality of connection sections further includes a first transition section and a second transition section. The first transition section is connected between the first connection section and the second connection section, and the second transition section is connected between the first connection section and the third connection section.

[0012] In some embodiments, the included angle between the extending direction of the second connection section and the extending direction of the first connection section ranges from 45° to 135°, and the included angle between the extending direction of the third connection section and the extending direction of the first connection section ranges from 45° to 135°.

[0013] In some embodiments, the bending direction of the first transition section is opposite to the bending direction of the second transition section.

[0014] In some embodiments, a fixing hole is provided in the first connection section. The fixing hole penetrates the first connection section along the thickness direction of the first connection section. A first connection hole is provided in the second connection section. The first connection hole penetrates the second connection section along the thickness direction of the second connection section. A second connection hole is provided in the third connection section. The second connection hole penetrates the third connection section along the thickness direction of the third connection section.

[0015] In some embodiments, the conductive bar includes a conductive body and a wear-resistant layer covering the surface of the conductive body, and the surface roughness of the conductive body is Ra ≦ 1.6 μm.

[0016] In some embodiments, the material of the conductive body is an aluminum alloy, and the aluminum alloy includes components with the following mass percentages, namely, 0.02% to 0.85% of Mg, 0.01% to 0.41% of Si, 0.01% to 0.04% of B, 0.01% to 0.062% of Fe, 0 to 0.096% of Zn, 0 to 0.0096% of Ti, 0 to 0.1% of Ni, 98.52% to 99.95% of Al, and impurities, and the content of impurities is ≦ 0.1%.

[0017] In some embodiments, the Vickers hardness of the surface of the conductive body is HV > 38.

[0018] In some embodiments, the conductive bar further includes a backing layer, the backing layer covers the surface of the conductive body, and the wear-resistant layer is disposed on the surface of the backing layer away from the conductive body.

[0019] In some embodiments, the conductive bar further includes an insulating layer, and the insulating layer is disposed on the surface of the wear-resistant layer away from the conductive body.

[0020] In some embodiments, the conductive bar has a yield strength of ≧ 75 Mpa, a tensile strength of ≧ 114 Mpa, and a conductivity of ≧ 57% IACS.

[0021] In some embodiments, the conductive bar has a thermal conductivity coefficient ranging from 200 W / m·K to 230 W / m·K.

[0022] The present disclosure further provides a conductive bar assembly including a connection substrate and a plurality of the aforementioned conductive bars. The plurality of conductive bars are all attached to the connection substrate and are spaced apart from each other.

[0023] A plurality of conductive bars form a plurality of groups of conductive bars. Each group of conductive bars includes a plurality of conductive bars. The plurality of conductive bars in each group of conductive bars are parallel to each other.

[0024] The present disclosure further provides a vehicle electrical device system including two electrical devices and the aforementioned conductive bars. The conductive bars are electrically connected between the two electrical devices.

[0025] In the present disclosure, the formula

Number

[0026] FIG. 1 is a schematic structural layout diagram of a vehicle electrical device system according to an embodiment of the present disclosure.

Brief Description of the Drawings

[0027]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Mode for Carrying Out the Invention

[0028] Hereinafter, while referring to the accompanying drawings in the embodiments of the present disclosure, the technical solutions in the embodiments of the present disclosure will be clearly and completely described. It is obvious that the described embodiments are only some of the embodiments of the present disclosure, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present disclosure without creative efforts shall be included in the protection scope of the present disclosure.

[0029] FIG. 1 is a schematic structural layout diagram of a vehicle electrical device system 1 according to an embodiment of the present disclosure.

[0030] The vehicle electrical device system 1 can be used in a vehicle and includes a conductive bar assembly 1000 and a plurality of electrical devices 2000. The plurality of electrical devices 2000 can be electrically connected by the conductive bar assembly 1000. For example, the electrical device 2000 can be a battery, a transformer, a motor, a circuit breaker, an AC / DC system, a circuit breaker cabinet, a capacitor, or another device.

[0031] Specifically, the conductive bar assembly 1000 includes a connection substrate 100 and a plurality of conductive bars 200. The connection substrate 100 is an insulating substrate. All of the plurality of conductive bars 200 are attached to the connection substrate 100 and are spaced apart from each other. In this embodiment, the connection substrate 100 has an integral structure. FIG. 1 shows only a partial structure of the connection substrate 100. It can be understood that in other embodiments, the connection substrate 100 may have a plurality of separate structures. The plurality of conductive bars 200 form a plurality of conductive bar groups and also form three vertical columns as shown in the figure. Each conductive bar group includes a plurality of conductive bars 200. The plurality of conductive bars 200 in each conductive bar group are parallel to each other. The conductive bars 200 in various conductive bar groups are electrically connected to implement electrical connection between various conductive bar groups.

[0032] A plurality of electrical devices 2000 can be electrically connected by a plurality of conductive bars 200 to effect electrical connection among the plurality of electrical devices 2000. As shown in the figure, the electrical devices 2000 in each horizontal row are electrically connected by the conductive bars 200 to effect electrical connection among the electrical devices 2000. The plurality of electrical devices 2000 can be electrically connected by a conductive bar assembly 1000, and a three-dimensional layout of the electrical devices 2000 in space is implemented through electrical connection to various conductive bar groups.

[0033] FIG. 2 is a schematic structural diagram of a conductive bar 200 according to a first embodiment of the present disclosure. For example, the conductive bar 200 may be used in the vehicle electrical device - system 1 shown in FIG. 1.

[0034] For ease of explanation, it is defined that the longitudinal direction of the conductive bar 200 shown in FIG. 2 is the X - axis direction, the width direction is the Y - axis direction, and the thickness direction is the Z - axis direction. The X - axis direction, the Z - axis direction, and the Y - axis direction are perpendicular to each other.

[0035] The conductive bar 200 includes at least one connection section. In this embodiment, the conductive bar 200 has a planar plate shape. Three connection sections are provided, including a first connection section 210, a second connection section 220, and a third connection section 230. The extending direction of the first connection section 210 is parallel to a first direction. The extending directions of the second connection section 220 and the third connection section 230 are parallel to a second direction and are spaced apart and arranged at two opposite ends of the first connection section 210. In this embodiment, the first direction is the X - axis direction, the second direction is the Y - axis direction, and the second direction is perpendicular to the thickness direction of the first connection section 210.

[0036] The first connection section 210 has a width ω and a thickness δ. In some specific embodiments, the width ω is in the range of 10 mm to 30 mm, and the thickness δ is in the range of 1 mm to 10 mm. A fixing hole 211 is provided in the first connection section 210. The fixing hole 211 penetrates the first connection section 210 along the thickness direction of the first connection section 210. In order to implement a fixed connection between the conductive bar 200 and the connection substrate 100, a bolt or another fixture may pass through the fixing hole 211 and the through hole in the connection substrate 100 to fix the first connection section 210 to the connection substrate 100.

[0037] The second connection section 220 has a width ω and a thickness δ. In some specific embodiments, the width ω is in the range of 10 mm to 30 mm, and the thickness δ is in the range of 1 mm to 10 mm. A first connection hole 221 is provided in the second connection section 220. The first connection hole 221 penetrates the second connection section 220 along the thickness direction of the second connection section 220.

[0038] The third connection section 230 has a width ω and a thickness δ. In some specific embodiments, the width ω is in the range of 10 mm to 30 mm, and the thickness δ is in the range of 1 mm to 10 mm. A second connection hole 231 is provided in the third connection section 230. The second connection hole 231 penetrates the third connection section 230 along the thickness direction of the third connection section 230. To implement the electrical connection between one conductive bar 200 and two electrical devices 2000, a bolt or another fixture may pass through the first connection hole 221 to electrically connect the second connection section 220 to one electrical device 2000, and pass through the second connection hole 231 to electrically connect the third connection section 230 to the other electrical device 2000. The first connection hole 221 and the second connection hole 231 are arranged such that the conductive bar 200 can be fixedly connected to the electrical device 2000 by a bolt or another fixture, which facilitates inspection and repair after sales, and solves the problem of inconvenience in assembly and disassembly due to the need to use welding for connection in the existing conductive bar 200.

[0039] It can be understood that, to implement the electrical connection between two electrical devices 2000 by two conductive bars 200, a bolt or another fixture may pass through the first connection hole 221 of one conductive bar 200 and the second connection hole 231 of the other conductive bar 200 to fixedly connect the two conductive bars 200.

[0040] FIG. 3 is a schematic structural diagram of the conductive bar 200 according to the second embodiment of the present disclosure. FIG. 4 is a schematic structural diagram of two conductive bars 200 having a bent radian of 45° that are connected. FIG. 5 is a schematic structural diagram of the conductive bar 200 shown in FIG. 3 from another viewing angle. FIG. 6 is a schematic cross-sectional view of the conductive bar 200 shown in FIG. 5 along A-A. For example, the conductive bar 200 may be used in the vehicle electrical device system 1 shown in FIG. 1.

[0041] As shown in FIG. 3, the conductive bar 200 in this embodiment has a three-dimensional structure, and the difference from the conductive bar 200 in the first embodiment is that the conductive bar 200 in this embodiment further includes a first transition section 241 and a second transition section 242. Specifically, in this embodiment, the conductive bar 200 in this embodiment includes a first connection section 210, a second connection section 220, a first transition section 241, a second transition section 242, and a third connection section 230. The first transition section 241 is connected between the first connection section 210 and the second connection section 220 to enable the first connection section 210 and the second connection section 220 to be arranged in different planes. The second transition section 242 is connected between the first connection section 210 and the third connection section 230 to enable the first connection section 210 and the third connection section 230 to be arranged in different planes.

[0042] In this embodiment, the first connection section 210, the second connection section 220, and the third connection section 230 all have a strip shape. The first connection section 210 extends in the X-axis direction, the second connection section 220 extends in the negative Z-axis direction, and the third connection section 230 extends in the positive Z-axis direction. The first connection section 210 has a width ω and a thickness δ. In some specific embodiments, the width ω is in the range of 10 mm to 30 mm, and the thickness δ is in the range of 1 mm to 10 mm. In this embodiment, the first transition section 241 has an arc-shaped surface and has a bending radius R and a bending radian θ. The cross-sectional shape of the arc-shaped surface is an arc, the bending radius R is the radius corresponding to this arc, and the bending radian is the curvature corresponding to this arc. In some specific embodiments, the bending radius R of the first transition section 241 is in the range of 2 mm to 20 mm. A large bending radius R is used as the transition radius so that stress concentration can be effectively reduced, thereby effectively improving the fatigue strength of the conductive bar 200. The bending radian θ of the first transition section 241 is 90° in order to enable the included angle between the extending direction of the second connection section 220 and the extending direction of the first connection section 210 to be 90°. Specifically, the second connection section 220 extends in the negative Z-axis direction and is parallel to the thickness direction of the first connection section 210. In other embodiments, the bending radian θ of the first transition section 241 may range from 45° to 135° in order to realize that the included angle between the extending direction of the second connection section 220 and the extending direction of the first connection section 210 ranges from 45° to 135°.

[0043] In this embodiment, the second transition section 242 has an arc-shaped surface and has a bending radius R and a bending radian θ. In some specific embodiments, the bending radius R of the second transition section 242 is within the range of 2 mm to 20 mm so that stress concentration is reduced, thereby effectively improving the fatigue strength of the conductive bar 200. The bending radian θ of the second transition section 242 is 90°, and is in a direction opposite to the bending direction of the first transition section 241 in order to reverse the extending directions of the second connection section 220 and the third connection section 230. Specifically, the third connection section 230 extends in the positive Z-axis direction and is parallel to the thickness direction of the first connection section 210. In other embodiments, the bending radian θ of the second transition section 242 may range from 45° to 135° in order to realize that the included angle between the extending direction of the third connection section 230 and the extending direction of the first connection section 210 ranges from 45° to 135°. In some specific embodiments, as shown in FIG. 4, the bending radian θ of the first transition section 241 and the second transition section 242 of the conductive bar 200 is 45°. The second connection section 220 of one conductive bar 200 and the third connection section 230 of the other conductive bar 200 can be connected by bolts or another fixture in order to implement a fixed connection between the two conductive bars 200.

[0044] The conductive bar 200 in this embodiment may be made by bending the conductive bar 200 in the first embodiment. Specifically, in order to manufacture and form the conductive bar 200 in the second embodiment, the second connection section 220 of the conductive bar 200 in the first embodiment bends in the negative Z-axis direction, and the third connection section 230 bends in the positive Z-axis direction. In other embodiments, the conductive bar 200 in this embodiment may be integrally formed.

[0045] FIG. 7 is a structural cross-sectional view of the first connection section 210 of the conductive bar 200 shown in FIG. 5.

[0046] The conductive bar 200 includes a conductive body 200a, a lining layer 200b, a wear-resistant layer 200c, and an insulating layer 200d. The lining layer 200b covers the surface of the conductive body 200a, the wear-resistant layer 200c is disposed on the surface of the lining layer 200b away from the conductive body 200a, the insulating layer 200d is disposed on the surface of the wear-resistant layer 200c away from the conductive body 200a, and the insulating layer 200d covers the portion of the conductive body 200a disposed in the first connection section 210. In the conductive bar 200 in this embodiment, it can be understood that the insulating layer 200d may cover the portions of the conductive body 200a disposed in the first transition section 241 and the second transition section 242. The insulating layer 200d does not cover the portions of the conductive body 200a disposed in the second connection section 220 and the third connection section 230 in order to ensure that the second connection section 220 and the third connection section 230 can be electrically connected to the electrical device 2000.

[0047] In the conductive bar 200 in this embodiment, the three-dimensional structure shown in FIG. 3 is formed by bending the conductive body 200a. Then, the conductive body 200a is sequentially electroplated to form the lining layer 200b and the wear-resistant layer 200c. Then, the insulating layer 200d covers the portions of the wear-resistant layer 200c disposed in the first connection section 210, the first transition section 241, and the second transition section 242 to manufacture and form the conductive bar 200.

[0048] The conductive body 200a is made of a conductive material, for example, made of an aluminum alloy. Since stress concentration occurs at a sudden change in the cross-sectional size of the conductive bar 200, in some specific embodiments, the surface roughness of the conductive body 200a is controlled such that Ra≤1.6 μm so that the fatigue strength of the conductive bar 200 can be improved, thereby avoiding the problem that the fatigue strength is impaired at the stress concentration of the conductive bar 200. Further, surface strengthening, such as shot blasting, is performed on the conductive body 200a so that a compressive prestress is generated on the surface of the conductive body 200a, thereby improving the fatigue resistance of the conductive bar 200. In some specific embodiments, shot blasting is performed on the conductive body 200a so that the Vickers hardness of the surface of the conductive body 200a is HV>38 to resist the influence caused by fatigue.

[0049] In some embodiments, the conductive body 200a is sequentially plated with copper and nickel in an electroplating manner to form a backing layer 200b and a wear-resistant layer 200c, respectively. In the electroplating process, copper ions in a positive valence state are reduced to metal atoms, attracted to the surface of the conductive body 200a, and move onto the surface of the conductive body 200a until they are incorporated into the crystal lattice to form the backing layer 200b. The electroplating process is performed under the "driving" by the difference between the reaction potential and the equilibrium potential so that the backing layer 200b is dense and flat and has good adhesion strength with the conductive body 200a to ensure the adhesion of the subsequent wear-resistant layer 200c and prevent the wear-resistant layer 200c from peeling off. In this embodiment, the wear-resistant layer 200c is a nickel layer, and the wear-resistant layer 200c has a thickness of 10 μm and a peeling strength of up to 35 N / mm. The nickel layer is arranged such that an excellent conductivity is guaranteed and at the same time a wear-resistant surface layer is obtained, thereby improving the strength of the conductive bar 200.

[0050] In this embodiment, the insulating layer 200d is manufactured on the wear-resistant layer 200c in the form of a spray coating. The insulating layer 200d is made of an epoxy resin layer and has a thickness ranging from 0.3 mm to 0.9 mm. The insulating layer 200d is arranged so that the creepage distance and the electrical clearance of the conductive bar 200 can be increased to ensure that the conductive bar 200 has a voltage resistance of 3000 V (AC), a leakage current of less than 3 mA for 60 seconds, an insulation resistance of 1000 V (DC), and a leakage insulation resistance of more than 200 mΩ for 60 seconds. In some embodiments, a sprayed code is manufactured on the insulating layer 200d, thereby improving the recognition and storage functions.

[0051] The conductive bar 200 provided in the embodiment of the present disclosure has good conductivity and mechanical properties. As a result, the problems of stress concentration occurring during long-term use under road conditions that cause vibration and the breakage of the conductive bar due to vibration during operation are avoided, thereby ensuring that the conductive bar assembly 1000 formed by using the conductive bar 200 is reliable and long-lasting, and also ensuring that the vehicle has a long total driving distance under actual road conditions.

[0052] 1.1 Selection of influencing factors related to the stress of the conductive bar Multiple factors are related to the stress performance of the conductive bar 200. The conductive bar 200 having the three-dimensional structure shown in FIG. 3 in the embodiments of the present disclosure was used as an experimental object for a simulation test to obtain the stress nephogram of the conductive bar 200. Further, a number of tests and experiments were conducted, and the relationship between the maximum stress and expansion rate, aging temperature, aging time, and elastic modulus E, etc. of the conductive bar 200 and influencing factors was investigated in particular. Some experimental results were collected as shown in Tables 1 to 4. The material of the conductive bar 200 is an aluminum alloy. The aluminum alloy is manufactured in the following manner, that is, by obtaining the raw material components of the aluminum alloy and performing solution treatment and aging treatment to obtain the aluminum alloy. The specific test method of the simulation test is as follows: The parameters of the conductive bar 200 and the parameters of the vibration experiment are incorporated into the finite element analysis element to conduct a simulation experiment on the conductive bar 200. The parameters of the vibration experiment include a vibration time of 22 h, a broadband vibration frequency ranging from 10 Hz to 1000 Hz, an output density within the range of [0.2 (m / s 2 ) 2 / HZ, 30 [(m / s 2 ) 2 / HZ], and an operating condition of a vibration condition root mean square (RMS, effective value of vibration velocity) of 27.8 m / s 2 . It is necessary that there is no mechanical damage and looseness after the experiment.

Table 1

Table 2

Table 3

Table 4

[0053] From Table 1 to Table 4, it can be seen that neither the expansion coefficient factor, the aging temperature factor, nor the aging time factor has a significant impact on the stress of the conductive bar 200, and the elastic modulus factor has a significant impact on the stress of the conductive bar 200. In the present disclosure, a large number of experimental investigations have been conducted, and the elastic modulus has been selected from many influencing factors as the main factor affecting the stress of the conductive bar 200. Having a slight stress and 2 The conductive bar 200 that can operate over a long period of time at broadband vibration frequencies ranging from 10 Hz to 1000 Hz under a vibration case with a vibration speed effective value (root mean square, RMS) exceeding 27.8 m / s can be designed by adjusting the elastic modulus, width, and thickness of the conductive bar 200.

[0054] 1.2 Optimization of the expressions of the elastic modulus E, width, and thickness of the conductive bar An aluminum alloy material was used to make the conductive bar 200 in the following experiment, and the relationship between the stress of the conductive bar 200 and the width ω, thickness δ, and elastic modulus E of the conductive bar 200 was specifically investigated. Specifically, the method of single-factor adjustment of the design of experiments (DOE) was used in the embodiments of the present disclosure, and multiple groups of conductive bars 200 with different widths ω, thicknesses δ, and elastic moduli E were designed, and simulation tests were performed on the conductive bars 200 to measure the stress of the conductive bars 200 in various groups. The stress nephograms of the stress nephograms 200 in experimental groups 1 to 12 are shown in FIGS. 8 to 19. The parameters of the conductive bar 200 and the measured maximum stress were collected as shown in Table 5. The conductive bars 200 in experimental groups 1 to 6 are conductive bars manufactured and formed by using the aluminum alloys provided in Embodiments 1 to 6 in Table 7 below, respectively. The conductive bar 200 in experimental group 7 is a conductive bar manufactured and formed by using the aluminum alloy provided in Embodiment 11 in Table 7 below. The conductive bars 200 in experimental groups 8 and 9 are conductive bars manufactured and formed by using the aluminum alloys provided in Embodiments 7 and 8 in Table 7 below, respectively. The conductive bars 200 in experimental groups 10 to 12 are conductive bars manufactured and formed by using the aluminum alloy provided in Comparative Ratio 1 in Table 7 below.

Table 5

[0055] In the embodiments of the present disclosure, by fitting a large amount of experimental data, the range of the thickness δ is optimized to satisfy the following characteristic formula (i), that is

Equation

[0056] From the data in several experimental groups shown in Table 5, for the conductive bar 200 in experimental groups 1 to 7, when the thickness δ satisfies the aforementioned characteristic formula (i) and the elastic modulus E satisfies the range of 55 GPa to 120 GPa, the measured stress of the conductive bar 200 is small, and it can be seen that the long-term vibration operating conditions can be satisfied. Furthermore, the thickness δ of the conductive bar 200 in experimental groups 1 to 7 satisfies the formula

Number

Number

Number

Number

Number

[0057] As can be known by comparing Experimental Groups 8 to 12 with Experimental Groups 1 to 7, in the case of the conductive bar 200 in Experimental Groups 8 and 9, the elastic modulus E satisfies the range of 55 GPa to 120 GPa, but the thickness δ does not satisfy the characteristic formula (i). The measured stress of the conductive bar 200 is very large and cannot meet the long-term vibration operation conditions. In the case of the conductive bar 200 in Experimental Groups 10 and 11, the elastic modulus E is all less than 55 GPa, and the thickness δ does not satisfy the characteristic formula (i). The maximum stress of the conductive bar 200 cannot be effectively reduced by adjusting the width ω or the thickness δ, and the long-term vibration operation conditions cannot be met. In the case of the conductive bar 200 in Experimental Group 12, the thickness δ satisfies the characteristic formula (i), but the elastic modulus E does not satisfy the range of 55 GPa to 120 GPa. The measured stress of the conductive bar 200 is small, and the long-term vibration operation conditions cannot be met. The experimental results [Number] Only the conductive bar 200 that satisfies both the range of the thickness δ that is [value] and the range of the elastic modulus E that is from 55 GPa to 120 GPa has a small stress and can meet the long-term vibration operation conditions, thereby indicating that the destruction of the conductive bar 200 caused by vibration during operation is avoided.

[0058] The conductive bar 200 in Experimental Group 1 is taken up. The bolt fixture (labeled as hole 1 - bolt) passes through the first connection hole 221, and the bolt fixture (labeled as hole 2 - bolt) passes through the second connection hole 231 to fix the conductive bar 200 to the vibration table. Then, a vibration experiment is conducted on the conductive bar 200. The conditions of the vibration experiment are a broadband vibration frequency ranging from 10 Hz to 1000 Hz, an output density within the range of [0.2 (m / s 2 ) 2 / HZ, 30 [(m / s 2 ) 2 / HZ], and a vibration speed of 27.8 m / s 2The vibration conditions are RMS and the vibration time is 22 h. The torque values of the bolt fixtures on the conductive bar 200 before and after the vibration experiment are measured, and the results are collected as shown in Table 6. The method for measuring the torque value of the bolt fixture is measured: 1. The torque of the bolt fixture before the vibration experiment is verified by using the tightening method, and the force is applied stably by using a wrest wrench, and the moment is gradually increased. When the bolt begins to produce a slight rotation, the instantaneous torque value of the bolt is the largest (because the force of static friction needs to be overcome). As the rotation continues, the torque value returns to a temporary stable state. In this case, the torque value is the detected torque value. 2. The torque of the bolt fixture after the vibration experiment is verified by using the loosening method. The torque is slowly applied to the bolt being verified by using a wrest wrench to loosen the bolt. The instantaneous torque value when the rotation starts is read, and a coefficient ranging from 1.1 to 1.2 is multiplied according to the experiment and experience to obtain the detected torque value.

Table 6

[0059] The torque attenuation value of the bolt fixture at Hole 1 is = (6.03 - 5.43) / 6.03×100% = 9.95% < 20%, and the torque attenuation value of the bolt fixture at Hole 2 is = (6.05 - 5.39) / 6.05×100% = 10.91% < 20%. The experimental results show a broadband vibration frequency ranging from 10 Hz to 1000 Hz, [0.2 (m / s 2 ) 2 / HZ, 30 [(m / s 2 ) 2 / HZ] of the output density, and 27.8 m / s 2After withstanding vibrations under the vibration condition RMS of the road conditions, the conductive bar 200 provided in the embodiments of the present disclosure can still maintain a fastener torque attenuation of less than 20%, indicating that this promotes the long-term use of the conductive bar 200 under actual vibrating road conditions.

[0060] 1.3 Optimization of the aluminum alloy material used in the conductive body 200a of the transition bus bar Each of Embodiments 1 to 11, and Comparative Ratio 1, provides a conductive bar 200, which is specifically manufactured by using the following steps, namely, the step of constructing the aluminum alloy raw material according to the components shown in FIG. 7, the step of performing a solution treatment at a temperature of 530°C for 25 minutes, and then the step of performing an aging treatment at a temperature of 195°C for 33 hours to obtain an aluminum alloy. Next, the aluminum alloy is cut to form the planar plate shape shown in FIG. 2, and then bent to obtain the conductive body 200a having the three-dimensional structure shown in FIG. 3. Grinding, polishing, and electroplating are sequentially performed to form the backing layer 200b and the wear-resistant layer 200c, and spray coating is performed to form the insulating layer 200d to obtain the conductive bar 200. The components of the aluminum alloy in Embodiments 1 to 11 and Comparative Ratio 1 are all calculated in mass percentages, and the rest is Al.

[0061] Performance tests were conducted on the conductive bars 200 manufactured in Embodiments 1 to 11 and Comparative Ratio 1, and the performance parameters of the conductive bars were collected as shown in Table 7. The International Annealed Copper Standard (IACS) is used to represent the conductivity of a metal or alloy (based on standard soft copper).

Table 7

[0062] The aluminum alloy material used for the conductive body 200a in the embodiments of the present disclosure contains the following components, namely, 0.02% to 0.85% of Mg, 0.01% to 0.41% of Si, 0.01% to 0.04% of B, 0.01% to 0.062% of Fe, 0 to 0.096% of Zn, 0 to 0.0096% of Ti, 0 to 0.1% of Ni, 98.52% to 99.95% of Al, and impurities, and the content of the impurities is ≦0.1%. In the case of the aluminum alloy materials made according to the formulations of the foregoing components in Embodiments 1 to 10, it can be known from the data in Table 7 that the elastic moduli of the aluminum alloy materials were all measured to be in the range of 55 GPa to 120 GPa.

[0063] In an aluminum alloy material, Si and Fe are added so that strengthening phases of Al3Fe and AlSiFe are formed in the aluminum alloy, thereby improving the material strength of the aluminum alloy. Si and Fe can increase the casting fluidity and the viscosity of the mold. However, when excessive Si and Fe are added, the conductivity is insufficient, and when insufficient Si and Fe are added, the strength is insufficient. Furthermore, Zn and Ni can increase the strength without reducing the conductivity of the aluminum alloy. In an embodiment of the present disclosure, the aluminum alloy material is controlled such that the content of Si is less than 0.5 wt.%, the content of Fe is less than 0.1 wt.%, the content of Ni is less than 0.1 wt.%, and the content of Zn is less than 0.1 wt.%, whereby it can have both mechanical properties and conductivity. Furthermore, the aluminum alloy material has high strength by controlling the content of impurity elements. After the aluminum alloy materials in Embodiments 1 to 10 of the present disclosure are bent by 90° (1t), the surfaces of the aluminum alloy materials have no cracks. Furthermore, according to measurement, the aluminum alloy materials in Embodiments 1 to 10 have a yield strength of ≧75 Mpa, a tensile strength of ≧114 Mpa, a conductivity of ≧57% IACS, and a thermal conductivity coefficient satisfying 200 W / m·K to 230 W / m·K, and have good mechanical properties and conductivity, thereby solving the problem that existing aluminum alloy materials have better conductivity while having lower mechanical properties. Furthermore, the aluminum alloy material has a lower density than a copper material and has the advantages of low density and light weight. The conductive bar 200 manufactured by using the aluminum alloy material provided in the embodiment of the present disclosure satisfies the lightweight development requirements of modern vehicles.

[0064] Furthermore, according to the comparison between Embodiments 1 to 10 and Embodiment 11, the elastic modulus of the conductive bar 200 manufactured by using the aluminum alloy material provided in Embodiment 11 satisfies from 55 GPa to 120 GPa. As shown in Experimental Group 7, the thickness δ is adjusted to satisfy the characteristic formula (i) so that a conductive bar 200 having a slight stress can be obtained. However, compared with the conductive bar 200 according to the formulation of the aluminum alloy in Embodiments 1 to 10, the Mg content in the formulation of the aluminum alloy material provided in Embodiment 11 is at most 9.2%, and both the conductivity and the thermal conductivity coefficient of the obtained conductive bar 200 are decreased. Compared with Embodiment 11, the conductive bar 200 in Embodiments 1 to 10 has both good mechanical properties and better conductivity, and has better applicability in vehicle electrical device systems.

[0065] According to the comparison between Embodiments 1 to 10 and Comparative Example 1, the alloy material provided in Comparative Example 1 has a small elastic modulus and a small thermal conductivity coefficient that does not contribute to enhancing the mechanical properties and the heat dissipation effect of the conductive bar 200. The aluminum alloy material in Embodiments 1 to 10 has a thermal conductivity coefficient ranging from 200 W / m·K to 230 W / m·K, has better conductivity, and further contributes to enhancing the heat dissipation effect of the conductive bar 200.

[0066] What is disclosed above is merely exemplary embodiments of the present disclosure and is not surely intended to limit the scope of the claims of the present disclosure. Those skilled in the art will understand that all or some of the processes of the foregoing embodiments are implemented, and that equivalent variations made according to the scope of the claims of the present disclosure still fall within the scope of the present disclosure.

Claims

1. A conductive bar (200) configured to be electrically connected between two electrical devices (2000), comprising at least one connection section, wherein the elastic modulus of the connection section is E, the width of the connection section is ω, the thickness of the connection section is δ, and the thickness δ of the connection section satisfies 【Number 1】 where λ = 0.085 GPa / mm, the units of both ω and δ are mm, the unit of E is GPa, and E is in the range of 55 GPa to 120 GPa. The conductive bar (200).

2. A plurality of connection sections are provided, the plurality of connection sections comprising a first connection section (210), a second connection section (220), and a third connection section (230), wherein the second connection section (220) and the third connection section (230) are respectively disposed at two opposite ends of the first connection section (210) and are respectively configured to be electrically connected to the two electrical devices (2000). The conductive bar (200) according to Claim 1.

3. The extending direction of the first connection section (210) is parallel to a first direction, the extending directions of the second connection section (220) and the third connection section (230) are both parallel to a second direction, and the first direction is perpendicular to the second direction. The conductive bar (200) according to Claim 2.

4. Having a planar plate shape, and the second direction is perpendicular to the thickness direction of the first connection section (210). The conductive bar (200) according to Claim 3.

5. Having a three-dimensional structure, and the second direction is parallel to the thickness direction of the first connection section (210). The conductive bar (200) according to Claim 3.

6. The plurality of connection sections further comprise a first transition section (241) and a second transition section (242), wherein the first transition section (241) is connected between the first connection section (210) and the second connection section (220), and the second transition section (242) is connected between the first connection section (210) and the third connection section (230). The conductive bar (200) according to Claim 2.

7. The included angle between the extending direction of the second connection section (220) and the extending direction of the first connection section (210) ranges from 45° to 135°, and the included angle between the extending direction of the third connection section (230) and the extending direction of the first connection section (210) ranges from 45° to 135°. The conductive bar (200) according to claim 6.

8. The bending direction of the first transition section (241) is opposite to the bending direction of the second transition section (242). The conductive bar (200) according to claim 6 or 7.

9. A fixing hole (211) is provided in the first connection section (210), the fixing hole (211) penetrates the first connection section (210) along the thickness direction of the first connection section (210), a first connection hole (221) is provided in the second connection section (220), the first connection hole (221) penetrates the second connection section (220) along the thickness direction of the second connection section (220), a second connection hole (231) is provided in the third connection section (230), and the second connection hole (231) penetrates the third connection section (230) along the thickness direction of the third connection section (230). The conductive bar (200) according to any one of claims 2 to 6.

10. Comprising a conductive body (200a) and an anti-wear layer (200c) covering the surface of the conductive body (200a), and the roughness of the surface of the conductive body (200a) is Ra≤1.6 μm. The conductive bar (200) according to any one of claims 1 or 9.

11. The material of the conductive body (200a) is an aluminum alloy, and the aluminum alloy comprises components with the following mass percentages, namely, 0.02% to 0.85% of Mg, 0.01% to 0.41% of Si, 0.01% to 0.04% of B, 0.01% to 0.062% of Fe, 0 to 0.096% of Zn, 0 to 0.0096% of Ti, 0 to 0.1% of Ni, 98.52% to 99.95% of Al, and impurities, and the content of the impurities is ≤0.1%. The conductive bar (200) according to claim 10.

12. The Vickers hardness of the surface of the conductive body (200a) is HV>38. The conductive bar (200) according to claim 10.

13. It further includes a lining layer (200b), the lining layer (200b) covers the surface of the conductive body (200a), and the wear-resistant layer (200c) is disposed on the surface of the lining layer (200b) away from the conductive body (200a). The conductive bar (200) according to any one of claims 10 or 12.

14. It further includes an insulating layer (200d), and the insulating layer (200d) is disposed on the surface of the wear-resistant layer (200c) away from the conductive body (200a). The conductive bar (200) according to claim 10.

15. The conductive bar (200) according to any one of claims 1 to 14, having a yield strength of ≥ 75 MPa, a tensile strength of ≥ 114 MPa, and a conductivity of ≥ 57% IACS.

16. The conductive bar (200) according to any one of claims 1 to 14, having a thermal conductivity coefficient ranging from 200 W / m·K to 230 W / m·K.

17. It includes a connection substrate (100) and a plurality of conductive bars (200) according to any one of claims 1 to 16. All of the plurality of conductive bars (200) are attached to the connection substrate (100) and are spaced apart from each other. A conductive bar assembly (1000).

18. The plurality of conductive bars (200) form a plurality of conductive bar groups. Each conductive bar group includes a plurality of conductive bars (200). The plurality of conductive bars (200) in each conductive bar group are parallel to each other. The conductive bar assembly (1000) according to claim 17.

19. It includes two electrical devices (2000) and a conductive bar (200) according to any one of claims 1 to 16. The conductive bar (200) is electrically connected between the two electrical devices (2000). A vehicle electrical device system (1).

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