Busbar Terminal Plug-in Structure for Corrosion Control
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Solution Overview
Problem
The high cost and inefficiency of connecting aluminum busbars to copper terminals due to electrochemical corrosion and complex welding processes, and the need for a stable and cost-effective plug-in structure in motor vehicles.
Innovation Solution
A plug-in structure for busbars and terminals using a transition layer to reduce electrochemical reactions, multiple laminated terminal connections with deformable arms, and a tellurium-copper alloy for improved conductivity and elasticity, along with a plating layer for enhanced corrosion resistance and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum busbar is directly connected to copper terminal through friction welding or ultrasonic welding, then electrochemical corrosion is reduced, but the process complexity and processing cost increase
Solution Approach 1:
The patent introduces a transition layer made of aluminum alloy as an intermediary between the aluminum busbar and copper terminal. This transition layer has intermediate electrochemical potential between aluminum and copper, reducing the potential difference and preventing galvanic corrosion. The transition layer is connected to the aluminum busbar through friction welding and to the copper terminal through ultrasonic welding, thereby reducing the complexity of direct welding between dissimilar metals.
2Reliability
If copper terminal is used to connect aluminum busbar, then electrical conductivity is improved, but the cost increases
Solution Approach 1:
The patent segments the connection structure into three parts: aluminum busbar, aluminum alloy transition layer, and copper terminal. This segmentation allows each component to be optimized for its specific function while using materials appropriately. The aluminum alloy transition layer uses less expensive aluminum-based material instead of requiring the entire connection to be copper, thereby reducing material cost while maintaining electrical conductivity through the optimized transition layer design.
3Strength
If friction welding or ultrasonic welding is used to connect aluminum busbar and copper terminal, then connection strength is improved, but the processing time and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the transition layer with friction welding to the aluminum busbar before final assembly with the copper terminal via ultrasonic welding. This staged approach allows each welding operation to be optimized and performed under ideal conditions, reducing rework and improving overall processing efficiency. The transition layer is prepared in advance with proper geometry and surface treatment, making the subsequent ultrasonic welding faster and more reliable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe, fast, and cost-effective plugging and unplugging of busbars to terminals, ensuring stable electrical connections with reduced corrosion and temperature rise, while optimizing material usage and processability.
Implementation Method 1
Due to the large potential difference between copper and aluminum, electrochemical corrosion is prone to occur
Implementation Method 2
The plug-in terminal of the present disclosure adopts a plating layer, which can better increase anti-corrosion performance
Implementation Method 3
A gap is arranged between the overhanging arms of the present disclosure to dissipate heat through the gap, so as to control the temperature rise between the busbar and the plug-in terminal
Implementation Method 4
The plug-in terminal of the present disclosure adopts tellurium-copper alloy, so that the terminal has good conductive performance
Data Source
Figure 1A
Figure 1B~2
Figure 3~4
AI summary
The present disclosure provides a plug-in structure of a busbar and a terminal, and a motor vehicle, relating to the technical field of electrical connection elements. The plug-in structure of the busbar and the terminal includes: a busbar and a plug-in terminal, the busbar is provided with a plug-in portion; the plug-in terminal includes at least one terminal lamination; the terminal lamination includes a plug-in end, and a connection end for being connected to a cable, and the plug-in portion is constructed to be in plug-in fit with the plug-in end. According to the present disclosure, the technical problem that the busbar can only be connected to other terminals or electrical devices through copper terminals is solved.