CN114665298B - New energy vehicle-mounted high-power direct-current connector of aluminum alloy conductor and manufacturing method - Google Patents
New energy vehicle-mounted high-power direct-current connector of aluminum alloy conductor and manufacturing method Download PDFInfo
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- CN114665298B CN114665298B CN202210361646.7A CN202210361646A CN114665298B CN 114665298 B CN114665298 B CN 114665298B CN 202210361646 A CN202210361646 A CN 202210361646A CN 114665298 B CN114665298 B CN 114665298B
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- 239000004020 conductor Substances 0.000 title claims abstract description 81
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 58
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000007787 solid Substances 0.000 claims description 51
- 238000009413 insulation Methods 0.000 claims description 42
- 230000015556 catabolic process Effects 0.000 claims description 14
- 238000005452 bending Methods 0.000 claims description 13
- 238000002474 experimental method Methods 0.000 claims description 11
- 229920002313 fluoropolymer Polymers 0.000 claims description 9
- 239000012535 impurity Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 9
- 229920000098 polyolefin Polymers 0.000 claims description 8
- 238000004132 cross linking Methods 0.000 claims description 7
- 238000007493 shaping process Methods 0.000 claims description 7
- -1 aluminum-magnesium-silicon Chemical compound 0.000 claims description 6
- 239000004719 irradiation crosslinked polyethylene Substances 0.000 claims description 6
- 238000000034 method Methods 0.000 claims description 4
- 229910000676 Si alloy Inorganic materials 0.000 claims description 2
- 229920003020 cross-linked polyethylene Polymers 0.000 description 6
- 239000004703 cross-linked polyethylene Substances 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 6
- 230000007774 longterm Effects 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000005265 energy consumption Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000004813 Perfluoroalkoxy alkane Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/025—Contact members formed by the conductors of a cable end
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
- B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/003—Apparatus or processes specially adapted for manufacturing conductors or cables using irradiation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0036—Details
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/148—Selection of the insulating material therefor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/2806—Protection against damage caused by corrosion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Toxicology (AREA)
- Power Engineering (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Insulated Conductors (AREA)
Abstract
The invention relates to the technical field of electric connector manufacturing, and discloses a new energy vehicle-mounted high-power direct current connector of an aluminum alloy conductor and a manufacturing method thereof, which are used for manufacturing an integrated whole vehicle in a new energy automobile; meanwhile, the electric connector is simple in structure, convenient to install, excellent in fixability after being installed, free of influence on the electric connector due to vibration and the like of an automobile in operation, large in overall current-carrying capacity and high in electric safety, and meets the full-cycle life requirement of a new energy automobile.
Description
Technical Field
The invention relates to the technical field of manufacturing of electric connectors, in particular to a new energy vehicle-mounted high-power direct current connector of an aluminum alloy conductor and a manufacturing method thereof.
Background
The new energy automobile enterprises master the three-electricity core technology, which is only one basic requirement, but far from enough. The motor, electric control and battery technologies are basic technologies, the difficulty of the whole vehicle integration technology is higher, and the whole vehicle manufacturing of the integrated whole vehicle with higher requirements for new energy is a peak of the vehicle technology.
The new energy vehicle-mounted electric connector is used as a connecting torsion strap of a new energy vehicle three-electric core technology, and the new energy vehicle-mounted high-power direct current connector based on the aluminum-based alloy conductor and the manufacturing method thereof can realize the special technical requirements of the new energy vehicle integrated whole vehicle manufacturing on the vehicle-mounted electric connector and have excellent popularization and application values by breaking through from electric connector materials, structures and manufacturing processes.
Disclosure of Invention
The invention mainly provides a new energy vehicle-mounted high-power direct current connector of an aluminum alloy conductor and a manufacturing method thereof.
In order to solve the technical problems, the invention adopts the following technical scheme:
the new energy vehicle-mounted high-power direct current connector of the aluminum alloy conductor comprises an aluminum alloy solid conductor;
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.38 to 0.49 percent, mg:0.4 to 0.58 percent, fe:0.32 to 0.48 percent, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities;
the resistivity of the aluminum alloy solid conductor is less than or equal to 0.0320 omega-mm 2 And/m, the conductivity is more than or equal to 55 percent IACS, the extensibility is more than or equal to 20 percent, and the bending radius reaches 2D-3D.
Further, the aluminum alloy solid conductor is made of an F-state or T4-T64-state aluminum-magnesium-silicon alloy solid rod material.
Further, the section of the aluminum alloy solid conductor is 50mm 2 ～500mm 2 。
Further, the cross section of the aluminum alloy solid conductor is round or rectangular.
Further, the aluminum alloy solid conductor comprises an insulating layer extruded outside the aluminum alloy solid conductor, wherein the concentricity of the insulating layer is more than or equal to 90%, no breakdown phenomenon exists when the insulating layer is subjected to 6-12 kV spark withstand voltage, no crack exists on the insulating surface after the insulating layer is bent to a radius of 2-3D by the applied holding force of 500-1000N, and no breakdown exists when the insulating layer is subjected to voltage insulation of 5kV/5 min.
Further, the insulating layer is made of crosslinked polyethylene, irradiation crosslinked polyolefin or PFA fluoroplastic material.
Further, the insulating thickness of the crosslinked polyethylene or the irradiation crosslinked polyethylene and the irradiation crosslinked polyolefin is 2.0 mm-4.0 mm, and the insulating thickness of the PFA fluoroplastic is 0.8 mm-1.2 mm.
The manufacturing method of the new energy vehicle-mounted high-power direct current connector of the aluminum alloy conductor is characterized by comprising the following steps of:
a. shaping the aluminum alloy conductor, wherein the shaping amount is less than or equal to 1%;
b. and extruding an insulating layer outside the shaped aluminum alloy conductor to form an insulating wire core, wherein the concentricity of the extruded insulating layer is more than or equal to 90%, performing a 6-12 kV spark withstand voltage experiment, applying a holding force of 500-1000N to a finished product to bend the finished product to a radius of 2-3D, and performing a voltage insulating experiment of 5kV/5 min.
And c, further, performing irradiation crosslinking on the insulating wire core in the step b, wherein the insulating wire core is irradiation crosslinked polyethylene, the thermal extension of the insulating layer is controlled to be 15-25%, the tensile strength is greater than or equal to 13MPa, the elongation at break is greater than or equal to 250%, and a 6-12 kV spark withstand voltage experiment is performed.
The beneficial effects are that: 1. the solid aluminum alloy conductor material adopts solid aluminum-magnesium-silicon rods in the F state or the T4-T64 state, the elongation is more than or equal to 20 percent, and the resistivity is less than or equal to 0.0320 omega mm 2 The conductivity of the conductive material is greater than or equal to 55% IACS, the conductive material has strong plasticity and good corrosion resistance, the wiring is convenient and reliable after the finished product is manufactured, the electric corrosion resistance at the wiring end is realized, the operation safety is high, the service life of the electric connector is prolonged, and simultaneously, the conductive material adopts a solid rod structure and is compared with the conductor profile section body of a stranded structure under the same current carrying capacityThe product is reduced by about 15 percent, compared with the conductor profile section of the compound twisted structure, the volume of the conductor profile section is reduced by about 25 percent, and the diameter shrinkage is obvious; 2. the insulating layer is mainly selected from crosslinked polyethylene, irradiation crosslinked polyolefin and PFA fluoroplastic, so that the product has wide temperature resistant range and can cover the electrical connector under different temperature resistant grades; 3. the electric connector is designed through the integral structure, the electric connector is simple and practical in structure, and the outer diameter of the electric connector is reduced by 15-20%: the weight of the electric connector is reduced by 45-55%, the laying space and the loading weight of the electric connector of the new energy automobile integrated whole automobile are effectively reduced, the energy consumption is reduced, meanwhile, the electric connector has certain mechanical plasticity and fixability, can be well combined with the new energy automobile integrated whole automobile, and has excellent laying performance and stability after laying; 4. the electric connector has good bending performance, the tensile strength after irradiation is greater than or equal to 13MPa, the elongation at break is greater than or equal to 250%, the minimum bending radius of the electric connector can reach 2D-3D, the electric connector has good laying performance, the insulating surface is free from cracks after the holding force of 500N-1000N applied by the finished electric connector is bent to the radius of 2D-3D, and the electric connector is insulated and not broken down by 5kV/5min voltage; the electric connector conductor is suitable for being arranged and installed in a vehicle, meanwhile, the electric connector conductor adopts a solid rod, the electric connector conductor can be suitable for processes such as flattening, stamping, punching, screwing, welding and the like in subsequent continuous processing, the end head can be randomly adjusted and designed according to the structural requirement of the connector in the vehicle and connected, accessories such as a connector terminal of the electric connector can be omitted, and the additional cost of installing the electric connector is reduced.
Drawings
FIG. 1 is a schematic view of a rectangular electrical connector according to the present invention;
FIG. 2 is a schematic view of a circular electrical connector according to the present invention;
reference numerals: an aluminum alloy solid conductor 1 and an insulating layer 2.
Detailed Description
The technical scheme of the novel energy vehicle-mounted high-power direct current connector of the aluminum alloy conductor and the manufacturing method thereof are further described in detail in the following by combining the embodiment; in the embodiment of the present invention, the impurities may refer to impurities that may not be intentionally introduced during the manufacturing process of the aluminum alloy, or may be unintentionally contained in each element itself.
Embodiment one:
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.49%, mg:0.41%, fe:0.38%, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities.
The resistivity of the aluminum alloy solid conductor is 0.0320 omega-mm 2 And/m, the conductivity is 55% IACS, the extensibility is 20.4%, and the bending radius reaches 2D-3D.
The insulating layer extruded outside the aluminum alloy solid conductor adopts crosslinked polyethylene, so as to meet the requirement of long-term working at 90 ℃. The insulation thickness is 2.3mm, the concentricity is 93.7%, no breakdown phenomenon exists after the insulation is subjected to 6kV spark withstand voltage, no crack exists on the insulation surface after the insulation is bent to the radius of 3D by the applied holding force of 700N, and the insulation is not broken down after the insulation is subjected to voltage insulation of 5kV/5 min.
The cross section of the aluminum alloy solid conductor is rectangular. Compared with a round structure, the rectangular structure occupies smaller space, the contact surface between the rectangular structure and the battery pack is larger, the rectangular structure is connected with the battery pack and is more fit, the rectangular structure has the same length and the same section of the electric connector, the space of the rectangular structure can be saved by 15% compared with the space of the round structure, and the fit degree of the rectangular structure is more than or equal to 75% compared with the fit degree of the round structure.
Embodiment two:
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.42%, mg:0.45%, fe:0.46%, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities.
The resistivity of the aluminum alloy solid conductor is 0.0318Ω·mm 2 And/m, the conductivity is 55.75% IACS, the extensibility is 21.06%, and the bending radius reaches 2D-3D.
The insulating layer extruded outside the aluminum alloy solid conductor adopts irradiation crosslinking polyethylene, and the requirement of long-term working at 125 ℃ and 150 ℃ is met through irradiation treatment. The insulation thickness is 3.1 and mm, the concentricity is 91.3 percent, no breakdown phenomenon exists after 12kV spark withstand voltage, no crack exists on the insulation surface after the insulation surface is bent to the radius of 3D by the applied holding force of 1000N, and the insulation does not break down after 5kV/5min voltage insulation.
After the insulating layer is irradiated, the tensile strength is 14.16MPa, the elongation at break is 256.7%, the insulating surface of the finished electric connector is ensured to be free from cracks after the finished electric connector is bent to a 3D radius, and the electric connector is not broken down when voltage of 5kV/5min is applied.
Embodiment III:
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.42%, mg:0.53%, fe:0.33%, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities.
The resistivity of the aluminum alloy solid conductor is 0.0312Ω·mm 2 And/m, the conductivity is 56.13% IACS, the extensibility is 21.19%, and the bending radius reaches 2D-3D.
The insulating layer extruded outside the aluminum alloy solid conductor is made of PFA fluoroplastic material, so that the requirement of long-term operation at 260 ℃ is met. The insulation thickness is 0.9mm, the concentricity is 93.4%, no breakdown phenomenon exists after the insulation is subjected to 6kV spark withstand voltage, no crack exists on the insulation surface after the insulation is bent to the radius of 2D by the applied holding force of 500N, and the insulation is not broken down after the insulation is subjected to voltage insulation of 5kV/5 min.
Embodiment four:
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.38%, mg:0.54%, fe:0.35%, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities.
The resistivity of the aluminum alloy solid conductor is 0.0296 omega-mm 2 And/m, the conductivity is 57.54% IACS, the extensibility is 23.61%, and the bending radius reaches 2D-3D.
The insulating layer extruded outside the aluminum alloy solid conductor adopts irradiation crosslinking polyolefin, so as to meet the requirement of long-term working at 90 ℃. The insulation thickness is 4.0mm, the concentricity is 90.4%, no breakdown phenomenon exists after 12kV spark withstand voltage, no crack exists on the insulation surface after the insulation surface is bent to 2D radius by the applied 1000N holding force, and the insulation is not broken down after 5kV/5min voltage insulation.
Fifth embodiment:
the aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.45%, mg:0.58%, fe:0.48%, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities.
The resistivity of the aluminum alloy solid conductor is 0.0307 Ω·mm 2 And/m, the conductivity is 56.61 percent IACS, the extensibility is 20.72 percent, and the bending radius reaches 2D-3D.
The insulating layer extruded outside the aluminum alloy solid conductor is made of PFA fluoroplastic material, so that the requirement of long-term operation at 260 ℃ is met. The insulation thickness is 1.2mm, the concentricity is 92.7%, no breakdown phenomenon exists after 12kV spark withstand voltage, no crack exists on the insulation surface after the insulation surface is bent to a 3D radius by the applied 800N holding force, and the insulation does not break down after 5kV/5min voltage insulation.
In the above embodiments, the cross-sectional area of the solid aluminum alloy conductor may be selected to be 50mm 2 ～500mm 2 The conductor effective section of the electric connector is designed according to the current-carrying requirement, so that the selected conductor section fully and effectively realizes the current-carrying capability required by the conductor, simultaneously, the weight and the volume of the electric connector can be effectively reduced, the cost is saved, and meanwhile, the conductor structure different from the conventional electric connector adopts a multi-strand stranded (compressed or not compressed) or special-shaped formed conductor and adopts a solid structure.
The cross section of the aluminum alloy solid conductor is round or rectangular, the rectangular structure occupies smaller space than the round structure, the contact surface between the aluminum alloy solid conductor and a battery pack is larger and connected in a vehicle, the aluminum alloy solid conductor is more fit to the battery pack, the electric connector with the same length and the same section can save 15% of space than the round structure, and the fit degree of the rectangular structure is more than or equal to 75% than that of the round structure. The rectangle includes a rectangle and a square.
Besides ensuring the electrical performance, the insulating layer also ensures certain mechanical protection performance, so that the insulating thickness of the crosslinked polyethylene or the irradiation crosslinked polyethylene and the irradiation crosslinked polyolefin is 2.0 mm-4.0 mm, and the insulating thickness of the PFA fluoroplastic is 0.8 mm-1.2 mm.
The manufacturing method of the electrical connector of the first to fifth embodiments is as follows:
a. shaping the aluminum alloy conductor, wherein the shaping amount is less than or equal to 1%;
the conductor is shaped, the shaping amount is not more than 1%, the conductor surfaces with different shaped cross sections are round or smooth, the surfaces are smooth, no greasy dirt and obvious oxidation and no burrs, cracks and the like are caused, the concentricity of the subsequent working procedure can be improved, the structural size of the product is ensured to meet the design requirement, and the insulation electrical property and the mechanical property of the electric connector are simultaneously met.
b. And extruding an insulating layer outside the shaped aluminum alloy conductor to form an insulating wire core, wherein the concentricity of the extruded insulating layer is more than or equal to 90%, performing a 6-12 kV spark withstand voltage experiment, applying a holding force of 500-1000N to a finished product to bend the finished product to a radius of 2-3D, and performing a voltage insulating experiment of 5kV/5 min.
The electric connector needs to be directly bent by applying mechanical external force on the insulating layer during installation, meanwhile, the electric safety performance of insulation needs to be ensured, the thickness of the insulating layer is designed to be 2.0-4.0 mm, the thickness of PFA is 0.8-1.2 mm, the concentricity of the insulating thickness is controlled to be more than 90%, the surface of an extruded insulating wire core is flat, other bad phenomena are avoided, and the electric connector has no breakdown phenomenon after 6-12 kV spark withstand voltage; the insulating surface has no crack after the holding force of 500N-1000N applied by the finished electric connector is bent to 2D-3D radius, and the insulating surface is not broken down after voltage insulation of 5kV/5 min.
And b, selecting the insulating wire core as irradiation crosslinking polyethylene or irradiation crosslinking polyolefin for irradiation crosslinking, controlling the thermal extension of the insulating layer to be 15-25%, controlling the tensile strength to be more than or equal to 13MPa, and performing a 6-12 kV spark withstand voltage experiment with the elongation at break to be more than or equal to 250%.
After the insulating layer is irradiated, the tensile strength is not less than 13MPa, the elongation at break is not less than 250%, and compared with the traditional electric connector, the tensile strength is 9-11 MPa, and the elongation at break is 125% -160%; when the strength is improved to above 13MPa, the 500N-1000N holding force applied during bending is prevented from damaging an insulating layer, 5kV/5min voltage insulation is applied to avoid breakdown, the insulating surface of a finished electric connector is ensured to be free of cracks after the electric connector is bent to a radius of 2-3D when the elongation is improved to above 250%, 5kV/5min voltage insulation is applied to avoid breakdown, the index requirement of the traditional electric connector cannot meet the bending radius requirement, and the voltage breakdown risk exists in insulation.
The above examples were subjected to resistivity and conductivity experiments according to GB/T3956 and elongation experiments according to GB/T228-2002, and the performance parameters are shown below:
as can be seen from the table, the solid aluminum alloy conductor has larger influence of Si on resistivity, and the overall resistivity of the solid aluminum alloy conductor is less than or equal to 0.0320 omega mm 2 M; the influence of Mg on the conductivity is larger, and Si can improve the conductivity when the content of Mg is almost equal to or higher than 55 percent IACS; the influence of Si on the elongation is large, the whole elongation is more than or equal to 20%, the spark withstand voltage is selected according to the insulation thickness, and the thicker the insulation thickness is, the smaller the concentricity is. Fe is used to increase strength and hardness.
The beneficial effects are that: 1. the solid aluminum alloy conductor material adopts solid aluminum-magnesium-silicon rods in the F state or the T4-T64 state, the elongation is more than or equal to 20 percent, and the resistivity is less than or equal to 0.0320 omega mm 2 The conductivity is greater than or equal to 55% IACS, the plasticity is strong, the corrosion resistance is good, the wiring is convenient and reliable after the finished product is manufactured, the electrical corrosion resistance at the wiring end is high, the operation safety is high, the service life of the electrical connector is prolonged, meanwhile, the solid rod structure is adopted, the volume of the conductor profile section of the twisted structure is reduced by about 15% compared with the conductor profile section of the twisted structure under the same current carrying capacity, the volume of the conductor profile section of the twisted structure is reduced by about 25% compared with the conductor profile section of the twisted structure, and the diameter reduction is obvious; 2. the insulating layer is mainly made of crosslinked polyethylene, irradiation crosslinked polyethylene and PFA fluoroplastic, so that the product has wide temperature resistant range and can cover the electrical connector under different temperature resistant grades; 3. the electric connector has simple and practical structure and outer diameter through the integral structural designThe reduction of 15-20 percent: the weight of the electric connector is reduced by 45-55%, the laying space and the loading weight of the electric connector of the new energy automobile integrated whole automobile are effectively reduced, the energy consumption is reduced, meanwhile, the electric connector has certain mechanical plasticity and fixability, can be well combined with the new energy automobile integrated whole automobile, and has excellent laying performance and stability after laying; 4. the electric connector has good bending performance, the tensile strength after irradiation is greater than or equal to 13MPa, the elongation at break is greater than or equal to 250%, the minimum bending radius of the electric connector can reach 2D-3D, the electric connector has good laying performance, the insulating surface is free from cracks after the holding force of 500N-1000N applied by the finished electric connector is bent to the radius of 2D-3D, and the electric connector is insulated and not broken down by 5kV/5min voltage; the electric connector conductor is suitable for being arranged and installed in a vehicle, meanwhile, the electric connector conductor adopts a solid rod, the electric connector conductor can be suitable for processes such as flattening, stamping, punching, screwing, welding and the like in subsequent continuous processing, the end head can be randomly adjusted and designed according to the structural requirement of the connector in the vehicle and connected, accessories such as a connector terminal of the electric connector can be omitted, and the additional cost of installing the electric connector is reduced.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (3)
1. The novel energy vehicle-mounted high-power direct current connector of the aluminum alloy conductor is characterized by comprising an aluminum alloy solid conductor, wherein the aluminum alloy solid conductor is of a solid rod structure and is made of F-state or T4-T64-state aluminum-magnesium-silicon alloy solid rod materials, and the section of the aluminum alloy solid conductor is 50mm 2 ～500mm 2 ；
The aluminum alloy solid conductor comprises the following components in percentage by weight: si:0.38 to 0.49 percent, mg:0.4 to 0.58 percent, fe:0.32 to 0.48 percent, cu: the content is less than 0.05%, mn: the content is less than 0.05%, cr: the content is less than 0.001%, ni: the content is less than 0.001%, zn: the content is less than 0.001%, and the balance is Al and unavoidable impurities;
the resistivity of the aluminum alloy solid conductor is less than or equal to 0.0320 omega-mm 2 The conductivity is larger than or equal to 55 percent IACS, the extensibility is larger than or equal to 20 percent, and the bending radius reaches 2D-3D;
the aluminum alloy solid conductor is characterized by further comprising an insulating layer extruded outside the aluminum alloy solid conductor, wherein the concentricity of the insulating layer is more than or equal to 90%, no breakdown phenomenon exists after 6-12 kV spark withstand voltage is achieved, no crack exists on the insulating surface after the insulating layer is bent to a radius of 2-3D by the applied holding force of 500-1000N, and no breakdown exists after 5kV/5min voltage insulation;
the insulating layer is made of irradiation crosslinked polyolefin, irradiation crosslinked polyethylene or PFA fluoroplastic material; the insulation thickness of the irradiation crosslinked polyethylene and the irradiation crosslinked polyolefin is 2.0 mm-4.0 mm, the insulation thickness of the PFA fluoroplastic is 0.8 mm-1.2 mm, the thermal extension of the insulation layer is controlled to be 15-25%, the tensile strength is greater than or equal to 13MPa, the elongation at break is greater than or equal to 250%, and no breakdown phenomenon exists when the 6-12 kV spark withstand voltage is carried out.
2. The electrical connector of claim 1, wherein: the cross section of the aluminum alloy solid conductor is round or rectangular.
3. The method for manufacturing the new energy vehicle-mounted high-power direct-current connector of the aluminum alloy conductor according to claim 1, comprising the steps of:
a. shaping the aluminum alloy conductor, wherein the shaping amount is less than or equal to 1%;
b. extruding an insulating layer outside the shaped aluminum alloy conductor to form an insulating wire core, wherein the concentricity of the extruded insulating layer is more than or equal to 90%, performing a 6-12 kV spark withstand voltage experiment, applying a holding force of 500-1000N to a finished product to bend the finished product to a radius of 2-3D, and performing a voltage insulating experiment of 5kV/5 min; the insulating layer is subjected to irradiation crosslinking, the thermal extension of the insulating layer is controlled to be 15-25%, the tensile strength is greater than or equal to 13MPa, the elongation at break is greater than or equal to 250%, and a 6-12 kV spark withstand voltage experiment is carried out.
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| DE2700275A1 (en) * | 1976-01-19 | 1977-07-21 | Olin Corp | ELECTRICAL CONNECTOR, IN PARTICULAR CONTACT SPRING |
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| WO2013065583A1 (en) * | 2011-11-02 | 2013-05-10 | 住友電気工業株式会社 | Aluminum alloy sheet for terminal, terminal fitting, and electric wire terminal connection structure |
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| CN109280824A (en) * | 2018-10-10 | 2019-01-29 | 彭嘉乐 | A kind of connecting terminal formula and its processing technology |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| DE2700275A1 (en) * | 1976-01-19 | 1977-07-21 | Olin Corp | ELECTRICAL CONNECTOR, IN PARTICULAR CONTACT SPRING |
| CN101914708A (en) * | 2010-08-20 | 2010-12-15 | 安徽省惠尔电气有限公司 | Al-Fe-Cu alloy material and preparation method thereof |
| WO2013065583A1 (en) * | 2011-11-02 | 2013-05-10 | 住友電気工業株式会社 | Aluminum alloy sheet for terminal, terminal fitting, and electric wire terminal connection structure |
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| CN109280824A (en) * | 2018-10-10 | 2019-01-29 | 彭嘉乐 | A kind of connecting terminal formula and its processing technology |
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Effective date of registration: 20240507 Address after: 238300 west side of Gaoxin Avenue, Dujiang industrial concentration zone, Nicha Town, Wuwei City, Wuhu City, Anhui Province Patentee after: ANHUI PACIFIC CABLE Co.,Ltd. Country or region after: China Address before: D-1707, floor 14, No. 116, Zizhuyuan Road, Haidian District, Beijing 100097 Patentee before: Beijing anchengtong Technology Development Co.,Ltd. Country or region before: China |