CN206962034U - A kind of joint of copper tip and aluminum conductor - Google Patents
A kind of joint of copper tip and aluminum conductor Download PDFInfo
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- CN206962034U CN206962034U CN201720642849.8U CN201720642849U CN206962034U CN 206962034 U CN206962034 U CN 206962034U CN 201720642849 U CN201720642849 U CN 201720642849U CN 206962034 U CN206962034 U CN 206962034U
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Abstract
A kind of joint of copper tip and aluminum conductor is the utility model is related to, the copper tip connector of the joint and the core of leading of aluminum conductor are connected by graded seal layer, and the joint is also provided with strengthening weld layer.The joint can increase conductance, and isolate copper tip and aluminum conductor, prevent that electrochemical reaction occurs between copper aluminium, extend the service life of copper tip and aluminum conductor joint, ensure machinery, the electric property of attachment structure.
Description
Technical field
The utility model belongs to wire harness field, is related to a kind of joint of copper tip and aluminum conductor.
Background technology
Copper have good electric conductivity, heat conduction, plasticity and be widely used.However, copper resource is short, copper cost is high.For
This, people begin look for the substitute of copper to reduce cost.Aluminium price is relatively low, and equally has excellent electric conductivity, leads
Heat and plastic working, it is the main trend developed at present for copper with aluminium therefore, but some performances of aluminium are still be not as excellent as copper
Different, many components still can not be completely with aluminium for copper, therefore weld between al member and copper component be present.Example
Such as, the wire being made up of aluminium class material uses as cable, in the copper tip by this cable connection on various electric devices
When, or when being attached mutually with copper cable, connected in copper aluminium contact jaw by welding.Copper tip one of the prior art
As include connector (or referred to as connection end), and the functor (or referred to as fixing end) of connector rear end；Connector is used
It is connected in aluminum conductor；Functor is used to be connected with electrical equipment terminal, such as automobile engine or battery.
Connection for aluminium and copper is conductive, has two technical problems never to solve：1) aluminium is active metal, in drying
The surface of aluminium forms dense oxidation film immediately in air, and aluminium is not further aoxidized simultaneously can be water-fast, but also make aluminum conductor simultaneously
Electric conductivity substantially reduce.2) copper belongs to different elements with aluminium, and the metal-inert of copper is greater than aluminium, existed between copper and aluminium
Relatively large difference in Electrode Potential, the connection of both metals easily occur electrochemical reaction after being powered, cause aluminum steel to be gradually oxidized,
Reduce the mechanical strength and electric conductivity of aluminum steel.
Existing wire harness often used in interconnection technique, and the connected mode of copper tip and wire is mainly based on crimping, i.e. wire
Lead core to be put into the connector of terminal, be crimped together terminal and wire by the way of machinery using terminal crimping mold.
However, for copper tip and this combination of aluminum conductor, traditional compression bonding method can not solve aluminum conductor and copper tip over time
The electrochemical reaction that is occurred of passage, the mechanical property and electricity of copper tip and aluminum conductor joint caused by can not solving thus
The problem of hydraulic performance decline.
Therefore, a kind of brand-new inexpensive solution copper tip and aluminum conductor joint are suddenly waited to release.
Utility model content
In order to overcome in the prior art, the connection of copper aluminium easily occur electrochemical corrosion, aluminium is oxidizable, strength of joint over time
The problem of elapsing and reducing, the utility model provide a kind of joint of copper tip and aluminum conductor.The joint can avoid copper aluminium
Electrochemical corrosion, the mechanical property and electric property of copper-aluminium joint are improved, increase the service life of copper-aluminium joint.
Above-mentioned purpose of the present utility model is realized by following technological means：
On the one hand, the utility model provides a kind of joint of copper tip and aluminum conductor, and described copper tip contains connection
Part, and the functor being connected with copper tip connector, the core of leading of the aluminum conductor is connected with copper tip connector, at least described
The core of leading of aluminum conductor be connected by graded seal layer with copper tip connector.The graded seal layer is made up of solder.Specifically
Ground, the graded seal layer are formed by the joint gap for after melt solder, being filled into copper tip connector and aluminum conductor.It is described
The fusion penetration depth of solder account for the 3%-100% of copper tip connector length；Preferably, the fusion penetration depth of described solder accounts for copper
The 30%-100% of terminal-connecting element length.
In the utility model, the joint of the copper tip and aluminum conductor has crimp region.Described crimp region face
Product at least accounts for the 1% of aluminum conductor and copper tip overlapping region area；Preferably, the crimping of described copper tip and aluminum conductor joint
Region area at least accounts for the 10% of aluminum conductor and copper tip overlapping region area.Described graded seal layer is made up of solder.
Described graded seal layer is formed by the joint gap for after melt solder, being filled into copper tip and aluminum conductor.Described solder
Fusion penetration depth account for the 5%-100% of whole crimp region length；Preferably, the fusion penetration depth of described solder accounts for whole crimping
The 35%-100% of zone length.
In joint of the present utility model and welding method, the metal material of the solder is not higher than the metal of aluminium for fusing point
Or alloy.As a preferred embodiment, the metal material of described solder contains zinc because the fusing point of zinc less than copper and
Aluminium, in process, when heating melting is carried out to solder, temperature, which can control, melts zinc, but not melts the copper end
Son and aluminum conductor joint, so as to influence the mechanical property of the joint and electric property, and zinc relative price is cheap.More preferably
Ground, described zinc account for more than the 30% of solder gross weight；It is highly preferred that described zinc accounts for more than the 60% of solder gross weight.
As a preferred embodiment, described copper tip and the joint of aluminum conductor, which also have, strengthens weld layer.It is excellent
Selection of land, described reinforcing weld layer parcel aluminum conductor lead the end face of core；Wherein, the thickness of described reinforcing weld layer is 0-
15mm；It is highly preferred that the thickness for strengthening weld layer is 1.5-5.5mm.
The joint of copper tip and aluminum conductor of the present utility model is by graded seal layer, or passes through graded seal layer and strong
Changing weld layer makes copper tip and aluminum conductor isolation come, and is effectively reduced the electrochemical corrosion of copper and aluminium.And strengthen weld layer bag
Wrap up in aluminum conductor end face, leading core and will not touching air and moisture for copper tip and wire, further reduce corrosion.In addition, transition
Weld layer and reinforcing weld layer tightly fix copper tip and aluminum conductor joint, effectively increase the pulling capacity of joint.
In the utility model, the material of described copper tip is copper or copper alloy；Preferably, described copper tip
Connector is the hollow columnar of flat, arcuation or both ends open, wherein, the side of hollow column can close or not
Closure.
As a preferred embodiment, the connector of described copper tip forms one with functor.Wherein, it is described
Connector be the part that is connected with aluminum conductor of copper tip；Wherein, described functor is that copper tip is connected with power device
FX, be that cable ends installation is fixed and realize the main region of copper tip and power device electrical connection.
As a preferred embodiment, coating is also contained on described copper tip surface；Preferably, described plating thickness
Spend for 3 μm to 5000 μm；More preferably 5 μm to 1000 μm.The coating can by plating, magnetic discharge welding, electric arc spraying or
The modes such as pressure welding are attached on copper tip.
Wherein, the thickness of the spaced metallization is 3 μm to 5000 μm.As preferred embodiment, spaced metallization
Thickness be 5 μm to 1000 μm between.If the thickness of spaced metallization is less than 3 μm, when crimping or welding, spaced metallization holds
Easily destroyed by copper tip and aluminum conductor, so that the contact of copper aluminium causes spaced metallization not play a part of being spaced copper and aluminium；
When spaced metallization thickness be more than 5000 μm, because the electric conductivity of most of spaced metallization material be not so good as copper and aluminium, be spaced
The thickness of metal level causes greatly the voltage drop of copper tip and aluminum conductor joint to raise；In addition, the dosage of interval metal can increase, into
This increase, but the electric property and mechanical property of copper tip and aluminum conductor joint are not significantly increased.In general, when using electricity
Plating or the mode fixed intervals metal level of electric arc spraying, the thickness of spaced metallization can reach 3 μm to 1000 μm；When using electricity
Magnetic welds or the mode of pressure welding, the thickness of spaced metallization can reach 1000 μm to 5000 μm；Therefore in the utility model between
It is arranged on every metal level in 3 μm to 5000 μm of thickness range.
The metal material of the coating is chromium or evanohm, zinc or kirsite, tin or tin alloy, titanium or titanium alloy, zirconium or
Zircaloy, nickel or nickel alloy, silver or silver alloy, the combination of gold or one or more of metals in billon；It is it is furthermore preferred that described
The metal material of coating is zinc or kirsite, tin or tin alloy, the combination of one or more of metals in nickel or nickel alloy.
In joint in the utility model, the core of leading of involved aluminum conductor can be aluminum or aluminum alloy.Described aluminium
Wire is solid conductor or multicore cable.
On the other hand, the utility model additionally provides the plasma welding method of the joint of above-mentioned copper tip and aluminum conductor,
The welding method comprises the following steps：
1) connector for leading core and copper tip of aluminum conductor is assembled；
2) connector for leading core and copper tip of aluminum conductor is compressed by the way of crimping, forms crimp region；
3) solder is delivered on copper tip；Preferably, solder is delivered on the connector of copper tip；Preferably, by solder
Deliver in the crimp region of aluminum conductor and copper tip, then welded using plasma arc welding (PAW), make solder fusing and made by capillary
Graded seal layer is formed with the joint gap for being filled into copper tip and aluminum conductor.
As another embodiment, can also first pre-filled solder, then be attached, specifically welding method include with
Lower step：
1) solder parcel aluminum conductor is led into core, or at least coated copper terminal-connecting element leads what core was connected with aluminum conductor
Part, then the core of leading of aluminum conductor is assembled with copper tip connector；
2) connector for leading core, solder and copper tip of aluminum conductor is compressed by the way of crimping, forms pressure
Connect region；
3) welded using plasma arc welding (PAW), make solder fusing between copper tip and aluminum conductor, and filled out by capillarity
The gap for being charged to copper tip and aluminum conductor forms graded seal layer.
As the preferred embodiment of above two mode, in step 3), welded using plasma arc welding (PAW), make solder
After fusing is initially formed reinforcing weld layer, continue welding process, fill solder is formed transition to the gap of copper tip and aluminum conductor
Weld layer；Preferably, the thickness of described reinforcing weld layer is 0-15mm；It is highly preferred that the thickness of described reinforcing weld layer
For 1.5-5.5mm.
In the method for the joint for preparing copper tip and aluminum conductor more than, also following supplementary notes：
In step 2), the crimp region area of described copper tip and aluminum conductor joint at least accounts for aluminum conductor and copper tip weight
The 1% of folded region area；Preferably, the crimp region area of described copper tip and aluminum conductor joint at least accounts for aluminum conductor and copper
The 10% of terminal overlapping region area；
In step 2), the aluminum conductor shrinkage factor after crimping is between 70%-90%, more preferably between 75%-85%.When
When the compression ratio of aluminum conductor is less than 70%, aluminum conductor is pressed into filament, and the pulling force born diminishes, and causes the machine of terminal and aluminum conductor
Tool performance deficiency, also, after aluminum conductor compacting, solder is difficult to enter into the gap of aluminum conductor, reduce solder to terminal and
The insulating effect of aluminum conductor；When compression ratio is higher than 90%, then the gap between aluminum conductor and copper tip is excessive, insufficient contact,
Cause the mechanical performance and electric property deficiency of aluminum conductor and copper tip joint.
In step 3), the ionization of described plasma weldering and protective gas can be nitrogen, argon gas, helium, neon, Krypton
Or xenon, more preferably argon gas；
In step 3), the welding current of described plasma weldering is between 5A-100A, between more preferably 20A-80A；
In step 3), the flow of ionized gas is 1-5 liters/min, and the flow of protective gas is 3-12 liters/min；It is more excellent
Choosing, the flow of ionized gas is 2-3 liters/min, and the flow of protective gas is 5-10 liters/min；
In step 3), the welding gun and the angle of copper tip axial direction of the weldering of described plasma are less than 45 °, more preferably less than 20 °；
In step 3), using after Plasma Welding, the fusion penetration of described solder is deep for described copper tip and aluminum conductor joint
Degree accounts for the 3%-100% of copper tip connector length；It is highly preferred that the fusion penetration depth of described solder accounts for copper tip connector length
The 30%-100% of degree；Experiments verify that to account for whole connector length ratio more for fusion penetration depth, the mechanical property of connector and
Electric property is better, when welding depth accounts for whole connector length ratio less than 3%, the mechanical property and electrical property of connector
It can significantly reduce.
In step 3), after Plasma Welding, the fusion penetration depth of described solder accounts for the 5%- of whole crimp region length
100%；Preferably, the fusion penetration depth of described solder accounts for the 35%-100% of whole crimp region length.It is experiments verify that molten
Deep degree accounts for that whole crimp region ratio is more, and the mechanical property and electric property of connector are better, when welding depth accounts for entirely
When crimp region ratio is less than 5%, the mechanical property and electric property of connector significantly reduce.
In step 3), described solder material is the metal or alloy that fusing point is not higher than aluminium；Preferably, described solder
Metal material is the metal or alloy that fusing point is not higher than aluminium；It is highly preferred that the metal material of described solder is zinc；More preferably
Ground, described zinc account for more than the 30% of solder gross weight；It is highly preferred that described zinc accounts for more than the 60% of solder gross weight.
Plasma arc welding (PAW) is coordinated solder to form graded seal layer by the utility model first, applied to copper tip and aluminum conductor
In joint.At present, the making of copper tip and aluminum conductor joint is main by the way of crimping, i.e., real using the mode of mechanical crimp
Existing connection between copper tip and aluminum conductor.In the production of wire harness field, it is unmanned at present using plasma arc welding (PAW) carry out copper tip with
The making of aluminum conductor joint.
First, simple plasma arc welding (PAW) welds obtained joint it is difficult to ensure that the welding of copper tip and aluminum conductor joint is strong
Degree and stability, wanting for requirement and stability in use of the wire harness to copper tip and the mechanical strength of aluminum conductor joint can not be met
Ask.If simple copper tip and aluminum conductor is contacted and welded, the fusing point of aluminium and copper is 660 DEG C and 1083 DEG C respectively, is being welded
Shi Buneng synchronously melts.The brittle metal compound of copper-rich metal etc in weld seam be present, welding quality is very poor, it is impossible to meets line
Requirement of the beam field to the electricity and mechanics of copper tip and aluminum conductor joint.
The graded seal layer that the utility model is obtained by solder and plasma arc welding (PAW) is applied in copper tip and aluminum conductor
In joint, it is ensured that the mechanical performance and electric property of copper tip and aluminum conductor joint.Importantly, solder fusing is led in aluminium
Line and the joint gap of copper tip coupling part form graded seal layer；Or described solder fusing is initially formed reinforcing welding
Continue welding process after layer, fill solder is formed graded seal layer to the gap of copper tip and aluminum conductor.
Graded seal layer makes aluminum conductor lead core and copper tip to completely cut off, and largely completely cut off copper tip and aluminum conductor joint and
The contact of outside air, water, efficiently avoid copper tip and leads core with aluminum conductor and directly contact generation electrochemical corrosion, pass through
Crossing weld layer reduces electrical potential difference between copper aluminium, improves the service life of copper tip and aluminum conductor joint, it is ensured that copper end
Son and the mechanical performance of aluminum conductor joint and the electric property of long-term use.Reinforcing weld layer in the utility model can enter one
The mechanical performance of step lifting copper tip and aluminum conductor joint, and isolation aluminum conductor completely can be played and lead core and outside air, water
Contact, further extend the service life of copper tip and aluminum conductor joint.
In addition, the stability of plasma arc welding (PAW), caloric value and temperature are all higher than in general arc welding.Compared in general electric arc
Weldering, has larger penetration power and speed of welding.Its weld interval shortens at least more than 20% compared with conventional arc weld interval, consumption
Electricity at least reduce by 30% and more than, significantly reduce the cost of manufacture of copper tip and aluminum conductor joint.
It is important to note that the leading before core welds to copper tip and aluminum conductor with solder and plasma arc welding (PAW),
Copper tip and aluminum conductor are first crimped, the mechanical property and electric property of copper aluminium connection terminal can be strengthened.Plasma arc welding (PAW) and weldering
Material is used in conjunction with, although can be with a certain degree of lifting mechanical property and electric property, however, because solder is only to melt
In the surface distributed of wire rod and the connection with copper tip is formed using capillarity afterwards, the lifting for performance is limited.As excellent
The embodiment of choosing, copper tip and aluminum steel are subjected to normal mechanical crimp, carry out PLASMA ARC WELDING afterwards, in enhancing mechanicalness
On the basis of energy, also reduce the electrical potential difference between copper aluminium using solder, so as to ensure electric property.Unexpectedly, solder
The mechanical property and electric property of plasma arc postwelding copper tip and aluminum conductor joint are enhanced with crimping collaboration.Especially prominent
It is when using more than 60% zinc as solder, to coordinate plasma arc welding (PAW) and crimping, the voltage of copper tip and aluminum conductor joint
It is 15% or so to drop the maximum range of decrease, and pulling capacity maximum amplification is 20% or so.
The advantage that the utility model obtains：
1st, plasma arc welding (PAW) combination solder is formed graded seal layer first and led applied to copper tip and aluminium by the utility model
The making of wire terminal, had both strengthened the mechanical performance and electric property of copper tip and aluminum conductor joint, and and can efficiently avoid
Copper tip and aluminum conductor lead the electrochemical corrosion that core directly contacts, and reduce the electrical potential difference between copper aluminium by graded seal layer,
Improve the service life of copper tip and aluminum conductor joint.
2nd, the reinforcing weld layer in the utility model can further lift the mechanical performance of copper tip and aluminum conductor joint,
And isolation aluminum conductor completely can be played and lead contact of the core with outside air and water, further extend copper tip and led with aluminium
The service life of wire terminal.
3rd, in using plasma arc welding (PAW) to the welding process of copper tip and aluminum conductor joint, the solder of fusing, heating
Copper tip enters one with aluminum conductor all in the oxygen and aluminum conductor in the inert gas shielding of plasma arc welding (PAW), completely cut off in air
Step oxidation, ensure that the electric property and service life of copper tip and aluminum conductor joint after welding；
4th, the leading before core welds to copper tip and aluminum conductor with solder and plasma arc welding (PAW), first crimps copper tip and aluminium
Wire, the mechanical property and electric property of copper aluminium connection terminal can be strengthened.The voltage drop of copper tip and aluminum conductor joint is maximum
The range of decrease is 15% or so, and pulling capacity maximum amplification is 20% or so.
5th, the stability of plasma arc welding (PAW), caloric value and temperature are all higher than in general arc welding.Compared in general arc welding,
With larger penetration power and speed of welding.Its weld interval shortens at least more than 20% compared with conventional arc weld interval, power consumption
Amount at least reduces by 30%, significantly reduces the cost of manufacture of copper tip and aluminum conductor joint.And plasma arc welding (PAW) process is steady
It is fixed, it is effectively guaranteed the quality of copper tip and aluminum conductor joint.
6th, required when traditional crimping mode makes copper tip and aluminum conductor joint copper tip connector be necessary for arcuation or
The hollow columnar of both ends open, and the utility model is applied to the making of variously-shaped copper tip and aluminum conductor joint, effectively
Solve crimping etc. mode make copper tip and limitation of the aluminum conductor joint in terms of copper tip shape selection.
Brief description of the drawings
Fig. 1 illustrates the example pattern of copper tip；
Fig. 2 illustrates the example pattern of aluminum conductor；
Fig. 3 illustrates the example pattern that aluminum conductor is connected with copper tip；
Fig. 4 illustrates to complete the example pattern of the copper tip after connecting and aluminum conductor top view；
Fig. 5 illustrates to complete the copper tip after welding and the example pattern in more core aluminum conductor vertical sections；
Fig. 6 illustrates to complete the copper tip after welding and the example pattern in solid aluminum conductor vertical section；
Fig. 7 illustrates to complete the copper tip after welding and the example pattern in aluminum conductor cross section；
The connector that Fig. 8 illustrates to be applicable in the utility model is barrel-shaped copper tip；
Example sample after the copper tip that Fig. 9 is illustrated in Fig. 8 welds according to the utility model method shows；
Figure 10 illustrates to complete the example pattern of the flat copper tip after connecting and aluminum conductor side view.
Also, Fig. 1 is as follows to 10 description of reference numerals：
1st, copper tip；1.1st, functor；1.2nd, connector；
2nd, aluminum conductor；2.1st, insulating barrier；2.2nd, aluminum core line；
3rd, graded seal layer；
4th, weld layer is strengthened；
5th, terminal coating.
Embodiment
The technical solution of the utility model is further illustrated below by way of specific embodiment, specific embodiment does not represent pair
The limitation of scope of protection of the utility model.Some nonessential modifications and tune that other people are made according to the utility model theory
It is whole to still fall within the scope of protection of the utility model.
The joint of a kind of 1 copper tip of embodiment and aluminum conductor
As illustrated in figures 1 and 8, the copper tip 1 contains connector 1.2, and the functor 1.1 of its rear end.
As shown in Fig. 2 the aluminum conductor 2 is multicore cable, it contains aluminum core line 2.2 and insulating barrier 2.1.
The core of leading of aluminum conductor 2 is connected with connector 1.2, specifically, the sectional side elevation of joint as shown in Figure 5.Before aluminum conductor
End and connector gap, containing graded seal layer 3, in the front end of aluminum conductor, also containing weld layer 4 is strengthened, it is complete to strengthen weld layer 4
Full parcel aluminum conductor front end surface, and form one with graded seal layer.
As shown in figure 3, the thickness of described reinforcing weld layer is 0-15mm；Preferably, the thickness for strengthening weld layer
For 1.5-5.5mm.
As shown in figure 5, the copper tip and aluminum conductor have crimp region between leading core, described crimp region area is at least
Account for the 1% of aluminum conductor and copper tip overlapping region area；Preferably, the crimp region face of described copper tip and aluminum conductor joint
Product at least accounts for the 10% of aluminum conductor and copper tip overlapping region area.
The joint of a kind of 2 copper tip of embodiment and aluminum conductor
Embodiment 1 is repeated, there is following difference：Described joint is without reinforcing weld layer.
The joint of a kind of 3 copper tip of embodiment and aluminum conductor
Embodiment 1 is repeated, there is following difference：As shown in Figure 10, the connector of described copper tip is shaped as flat,
The aluminum conductor is pre-stressed on copper tip by frock or mould, is welded using plasma arc welding (PAW), makes solder fusing in copper tip
Between aluminum conductor, and the gap for being filled into by capillarity copper tip and aluminum conductor forms graded seal layer.
The joint of a kind of 4 copper tip of embodiment and aluminum conductor
Embodiment 1 is repeated, there is following difference
As shown in figure 5, coating 5 is also contained on the surface of the copper tip；
Preferably, described thickness of coating is 3 μm to 5000 μm；It is highly preferred that described thickness of coating is 5 μm to 1000
μm；
Preferably, the coating is attached on copper tip by way of plating, magnetic discharge welding, electric arc spraying or pressure welding；
Described electric plating method, its step are：1st, coated metal is in anode；2nd, material to be plated is in negative electrode；3rd, anode and cathode
It is connected with the electrolyte solution of the positive metal ions composition of plating up；4th, after the power supply for passing to direct current, the metal of anode can oxygen
Change (losing electronics), the cation in solution then into atom and accumulates in negative electrode top layer in cathodic reduction (obtaining electronics).
The method of described magnetic discharge welding, its step are：1st, two kinds of metals for needing pressure welding are stacked；2nd, electromagnetism soldering equipment is welding
Connect region and form high voltage magnetic field, make two kinds of metals that the shock of atomic energy level occur under the promotion of electromagnetic force, so that two kinds of gold
Category welds together.
The method of described electric arc spraying, it is that interval metal is delivered to arc zone and is atomized, and in compressed gas
The lower high-velocity spray of effect forms arc spray coatings to workpiece surface.
The method of described pressure welding, its step are：1st, two kinds of metals for needing pressure welding are stacked；2nd, applying pressure makes table to be welded
Face is fully diffused and combined between realizing atom；3rd, it is different and pressure source is different regarding metal, can be by increasing the side of temperature
Method improves welding effect, shortens weld interval.
Preferably, the metal material of the coating is chromium or evanohm, and zinc or kirsite, tin or tin alloy, titanium or titanium close
Gold, zirconium or zircaloy, nickel or nickel alloy, silver or silver alloy, the combination of gold or one or more of metals in billon；More preferably
, the metal material of the coating is zinc or kirsite, tin or tin alloy, the group of one or more of metals in nickel or nickel alloy
Close.
The joint of a kind of 5 copper tip of embodiment and aluminum conductor
Embodiment 1 is repeated, such as Fig. 6, there is following difference：The aluminum conductor is solid conductor
The plasma welding method of a kind of 6 copper tip of embodiment and aluminum conductor
As shown in figure 1, copper tip 1 of the present utility model has functor 1.1, and the connector 1.2 being connected with functor.
In the present embodiment, connector is wing, and its end face is U-shape structure.
As shown in Fig. 2 aluminum conductor 2 of the present utility model has the insulating barrier 2.1 of multicore aluminium core 2.2 and outer layer, crimping
The preceding size according to copper tip has divested partial insulative layer.
Copper tip and aluminum conductor joint making step are specific as follows：
As shown in figure 3, aluminum conductor is divested into insulating barrier, it is put into copper tip aerofoil profile connector, and uses crimp will
Aluminum conductor and copper tip aerofoil profile connector are crimped, and described crimp region area at least accounts for aluminum conductor and copper tip overlay region
The 1% of domain area；Preferably, the crimp region area of described copper tip and aluminum conductor joint at least accounts for aluminum conductor and copper tip
The 10% of overlapping region area.
After crimping, aluminum conductor leads core compression ratio between 70%-90%；Preferably, aluminum conductor leads the compression ratio of core
Between 75%-85%, to ensure the mechanical performance and electric conductivity of copper tip and aluminum conductor joint, copper tip and aluminium after crimping
Terminal is as shown in Figure 4.
Specifically, solder is delivered on copper tip, it is preferable that deliver to solder on the connector of copper tip；Preferably, will
Solder is delivered in the crimp region of aluminum conductor and copper tip, is then welded using plasma arc welding (PAW), is made solder fusing and is passed through hair
Spy forms graded seal layer with the joint gap for being filled into copper tip and aluminum conductor.
The ionization of plasma weldering and protective gas can be nitrogen, argon gas, helium, neon, Krypton or xenon, more preferably
For argon gas；The flow of ionized gas is 1-5 liters/min, and the flow of protective gas is 3-12 liters/min；It is furthermore preferred that ionization gas
The flow of body is 2-3 liters/min, and the flow of protective gas is 5-10 liters/min；In welding process, the welding gun of plasma weldering
It is less than 45 °, more preferably less than 20 ° with the angle of copper tip axial direction；Plasma weldering welding current is 5A-100A, more preferably 20A-
80A；
In welding process, welding temperature central area can reach 400 DEG C~550 DEG C, solder fusing is initially formed reinforcing weldering
After connecing layer 4, continue welding process, fill solder is formed graded seal layer 3 to the gap of copper tip and aluminum conductor；Copper tip with
The profilograph of aluminum conductor joint end-state is as shown in Figure 5；The fusion penetration depth of described solder accounts for copper tip connector length
3%-100%；It is highly preferred that the fusion penetration depth of described solder accounts for the 30%-100% of copper tip connector length；It is preferred that
Ground, the fusion penetration depth of solder account for the 5%-100% of whole crimp region length, more preferably account for the 35%- of whole crimp region
100%.
The metal material of above-mentioned solder is the metal or alloy that fusing point is not higher than aluminium, the aluminum conductor so when welding melting
Leading core will not melt, and be led so that solder can penetrate into aluminum conductor by capillarity between core and copper tip, form transition
Weld layer or in the present embodiment, is initially formed reinforcing weld layer, rear to form graded seal layer.
As shown in fig. 7, the sectional elevation of the crimping portion of copper tip connector and aluminum conductor, wherein, solder closely melts
Close between copper tip connector and aluminum conductor, both ensure that isolation air and water lead the corrosion of core to aluminum conductor, effectively avoid
The electrochemical corrosion of air and water to copper tip and aluminum conductor joint, also good conduction can be carried out with copper and aluminium, ensure that copper
The mechanical performance of terminal and aluminum conductor joint, electric property and service life.
The plasma welding method of a kind of 7 copper tip of embodiment and aluminum conductor
Embodiment 6 is repeated, there is following difference, the connector of the copper tip is shaped as flat, arc structure, welding
When, first solder is delivered on copper tip, it is preferable that deliver to solder on the connector of copper tip；Preferably, solder is delivered into aluminium
In the crimp region of wire and copper tip, then welded using plasma arc welding (PAW), make solder fusing and filled by capillarity
Graded seal layer is formed to the joint gap of copper tip and aluminum conductor.The solder of melting is only filled with leading with aluminium to copper tip connector
The gap of line connection forms graded seal layer, does not form reinforcing weld zone.
The plasma welding method of a kind of 8 copper tip of embodiment and aluminum conductor
Embodiment 6 is repeated, there is following difference：
After 1. aluminum conductor divests insulating barrier, solid thin layer solder ring set is divested to leading on core for the aluminum conductor after insulating barrier,
The connector for being then placed in copper tip is crimped.
2. the connector of copper tip is the hollow columnar structures of both ends open, closure is in its side or does not close.
The connection method of a kind of 9 copper tip of embodiment and aluminum conductor
Embodiment 6 is repeated, there is following difference：
After aluminum conductor is divested into insulating barrier, solid thin layer solder parcel at least copper tip connector is led into core with aluminum conductor and connect
Tactile part, then the core of leading of aluminum conductor is put into the connector region of copper tip and crimped.
The influence of voltage drop and pulling capacity of the different connection method of embodiment 10 to copper tip and the joint of aluminum conductor
Using same size and the copper tip and aluminum conductor of structure, copper tip and aluminum conductor are made by following 5 kinds of methods
Joint, every kind of method make 10 exemplars, totally 50 exemplars.
Method 1：Crimping
Aluminum conductor is directly crimped onto in copper tip using mould.
Method 2：Plasma arc welding (PAW)
Using plasma arc welding (PAW), directly copper tip and aluminum conductor are welded together.The welding current of plasma arc welding (PAW) is
40A, the flow of ionized gas argon gas is 2.5 liters/min, and the flow of protective gas argon gas is 7.5 liters/min；Plasma weldering
Welding gun and 15 ° of the angle of copper tip axial direction.
Welding method 3：Crimping+plasma arc welding (PAW)
With reference to embodiment 6, aluminum conductor is crimped onto in copper tip using mould, plasma arc welding (PAW) is reused, after crimping
Copper tip and aluminum conductor weld together.After crimping, the compression ratio of aluminum conductor is 80%；The welding current of plasma arc welding (PAW) is
40A.The flow of ionized gas argon gas is 2.5 liters/min, and the flow of protective gas argon gas is 7.5 liters/min；Plasma weldering
Welding gun and 15 ° of the angle of copper tip axial direction.
Welding method 4：Plasma arc welding (PAW)+solder
Solder is delivered on the connector of copper tip, using plasma arc welding (PAW), copper tip and aluminum conductor welded together.
The welding current of plasma arc welding (PAW) is 40A；
Solder contains 90% zinc and 10% aluminium, and the flow of ionized gas argon gas is 2.5 liters/min, protective gas argon
The flow of gas is 7.5 liters/min；The welding gun of plasma weldering and 15 ° of the angle of copper tip axial direction.
Welding method 5：Crimping+plasma arc welding (PAW)+solder
Aluminum conductor is crimped onto in the connector of copper tip using mould.Solder is delivered on the connector of copper tip, made
With plasma arc welding (PAW), the copper tip crimped and aluminum conductor are welded together.The welding current of plasma arc welding (PAW) is 40A；Weldering
Expect the zinc and 10% aluminium for 90%；After crimping, the compression ratio of aluminum conductor is 80%, the flow of ionized gas argon gas for 2.5 liters/
Minute, the flow of protective gas argon gas is 7.5 liters/min；The welding gun of plasma weldering and 15 ° of the angle of copper tip axial direction.
After the joint that copper tip and aluminum conductor are made using above-mentioned 5 kinds of methods, voltage drop and drawing to 5 groups of totally 50 exemplars
Pull out force is tested using Homogeneous assay method, and the test parameter of every group of exemplar is averaged, and test result is shown in Table 1.
The voltage drop of copper tip and the joint of aluminum conductor that table 1 is made using 5 kinds of different preparation methods contrasts with pulling capacity
As shown in Table 1, the joint of copper tip and aluminum conductor is only by way of crimping is either only by plasma arc welding (PAW)
(method 1 and method 2) makes, and the pulling capacity of joint is relatively low, and voltage drop is higher, can not meet that copper tip and aluminum conductor joint make
The mechanics and electrical performance requirements that should reach in.Although the drawing of copper tip and aluminum conductor joint can be improved using method 3
Power, but its voltage drop is still higher, still can not meet the electrical property that the joint of copper tip and aluminum conductor should reach in use
It can require.Copper tip is met using the copper tip made by method 4 described in the utility model and method 5 and the joint of aluminum conductor
The mechanics and electrical performance requirements that should reach in use with aluminum conductor joint.It is readily apparent that using in the utility model
The mechanical property and electricity for the joint that the copper tip of crimping+plasma arc welding (PAW)+solder and the preparation method of aluminum conductor joint make
Performance is best in above-mentioned 5 kinds of methods.
Influence of the solder of the different zinc-base ratio of embodiment 11 to copper tip and aluminum conductor joint performance
Welding method is with reference to embodiment 6, using control variate method, welding current 40A, ionize the flow of argon gas for 3 liters/
Minute, the flow for protecting argon gas is 8 liters/min, and the compression ratio of aluminum conductor is 80%, welding gun and the copper tip axial direction of plasma weldering
15 ° of angle.Solder is made and connect with the copper tip of embodiment 3 and the preparation method of aluminum conductor joint in different zinc-base ratios
Head.The joint made is subjected to pulling capacity and fall-of potential test according to method of testing of the same race, every kind of exemplar makes 100, surveys
Examination takes its average value.Test result is shown in Table 2.
The influence of the solder butt joint performance of the different zinc-base ratio of table 2
As shown in Table 2, when the part by weight shared by zinc is higher, the voltage drop of copper tip and aluminum conductor is lower, i.e. copper end
The electric property of son and aluminum conductor joint is better.
When using zinc in zinc-base ratio to account for solder gross weight connecing for copper tip and aluminum conductor is made for more than 30% solder
During head, the pulling capacity performance of its joint meets the use mechanical property requirements of the joint of most copper tips and aluminum conductor.When
When using zinc in zinc-base ratio to account for solder gross weight to make the joint of copper tip and aluminum conductor for more than 60% solder, its joint
Pulling capacity performance can be fully achieved copper tip and aluminum conductor joint use mechanical property requirements.
The aluminum conductor of embodiment 12 leads influence of the core compression ratio for copper tip and aluminum conductor joint performance
In order to which that tests different aluminum conductors leads influence of the core compression ratio for copper tip and aluminum conductor joint performance, this reality
Apply example and use control variate method, made as shown in table 3 not using the copper tip of embodiment 6 and the preparation method of aluminum conductor joint
Same joint.Wherein, welding current 40A, the flow for ionizing argon gas is 3 liters/min, and the flow for protecting argon gas is 8 liters/min,
Solder contains 90% zinc and 10% aluminium, the welding gun and 15 ° of the angle of copper tip axial direction of plasma weldering.Obtained by every kind of method
The exemplar of joint is 10, and test takes its average value.Compression ratio and test result are shown in Table 3.
The different aluminum conductor of table 3 leads influence of the core compression ratio for copper tip and aluminum conductor joint performance
According to this table measured result, after crimping, aluminum conductor leads core compression ratio between 70% to 90%, copper tip and aluminium
The electric property and mechanical property of terminal are preferable.It is highly preferred that after crimping, the core compression ratio of leading of aluminum conductor arrives 75%
Between 85%, the electric property and mechanical property of copper tip and aluminum conductor joint are more prominent.
Shadow of the different reinforcing weld layer thickness of embodiment 13 to the pulling capacity and voltage drop of copper tip and aluminum conductor joint
Ring
In order to prove influence of the different reinforcing weld layer thickness to copper tip and aluminum conductor joint performance, 17 groups are made not
With reinforcing weld layer thickness exemplar, every group of exemplar 10, then by the pulling capacity of copper tip and aluminum conductor joint and
Fall-of potential test, the test result average value of every kind of reinforcing weld layer thickness is inserted in table, refers to table 4.
Welding method is 90% zinc and 10% aluminium with reference to embodiment 6, wherein solder, and the flow of ionized gas argon gas is
2.5 liters/min, the flow of protective gas argon gas is 7.5 liters/min；The welding gun of plasma weldering and the angle of copper tip axial direction
15°。
As can be seen from Table 4, after the reinforcing weld layer thickness of copper tip and aluminum conductor joint is more than 15mm, copper end
The pulling capacity and voltage drop performance of son and aluminum conductor joint start to be remarkably decreased.Therefore, it is 0- that weld layer thickness is strengthened in selection
15mm, when the thickness for strengthening weld layer is 1.5mm-5.5mm, the pulling capacity and voltage drop performance of copper tip and aluminum conductor joint
It is more excellent.
Influence of the different reinforcing weld layer thickness of table 4 to copper tip and aluminum conductor joint performance
Influence of the different solder fusion penetration depth of embodiment 14 to copper tip and aluminum conductor joint performance
In order to verify influence of the fusion penetration depth to the pulling capacity and voltage drop of copper tip and aluminum conductor joint, 44 groups are made not
With the welding exemplar of fusion penetration depth, every group of exemplar 10.
Welding method is 90% zinc and 10% aluminium with reference to embodiment 6, wherein solder, and the flow of ionized gas argon gas is
2.5 liters/min, the flow of protective gas argon gas is 7.5 liters/min；The welding gun of plasma weldering and the angle of copper tip axial direction
15°。
From table 5 below as can be seen that fusion penetration depth accounts for connector length ratio or bigger, the copper end that accounts for crimp region length ratio
The mechanical property and electric property of son and aluminum conductor joint are better, but are less than when welding depth accounts for crimp region length ratio
When 5%, or when welding depth accounts for connector length ratio less than 3%, the mechanical property and electricity of copper tip and aluminum conductor joint
Learning performance significantly reduces.When the fusion penetration depth of described solder accounts for the 35%- of the crimp region of copper tip and aluminum conductor joint
When 100%, or when the fusion penetration depth of described solder accounts for connector length ratio in 30%-100%, copper tip and aluminum conductor
The mechanical property and electric property of joint are preferable.
The different melt solder depth of table 5 is to copper tip and the influence of aluminum conductor joint pulling capacity and voltage drop
Influence of the different crimp region area of embodiment 15 to copper tip and aluminum conductor joint performance
In order to verify the pulling capacity of crimp region area butt joint of copper tip and aluminum conductor joint and the influence of voltage drop,
Make the welding exemplar of 12 groups of difference crimp region areas, every group of exemplar 10.
Welding method is 80% zinc and 20% aluminium with reference to embodiment 6, wherein solder, and the flow of ionized gas argon gas is
2.5 liters/min, the flow of protective gas argon gas is 7.5 liters/min；The welding gun of plasma weldering and the angle of copper tip axial direction
20°。
The different crimp region area of table 6 accounts for aluminum conductor and the ratio of copper tip overlapping region area is led to copper tip and aluminium
The pulling capacity of wire terminal and the influence of voltage drop
As can be seen from Table 6, it is overlapping with copper tip to account for aluminum conductor for the crimp region area of copper tip and aluminum conductor joint
The ratio of region area is more, and the mechanical property and electric property of connector are better, but when crimp region area accounts for aluminum conductor
When being less than 1% with the ratio of copper tip overlapping region area, the mechanical property and electric property of connector significantly reduce.Therefore,
Selection crimp region area at least accounts for the 1% of aluminum conductor and copper tip overlapping region area, it is preferable that described copper tip and aluminium
The crimp region area of terminal at least accounts for the 10% of aluminum conductor and copper tip overlapping region area.
Claims (23)
1. the joint of a kind of copper tip and aluminum conductor, described copper tip contains connector, and is connected with copper tip connector
Functor, the core of leading of the aluminum conductor is connected with copper tip connector, it is characterised in that at least described aluminum conductor leads core
It is connected by graded seal layer with copper tip connector.
2. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that described copper tip and aluminum conductor
Joint has crimp region, and described crimp region area at least accounts for the 1% of aluminum conductor and copper tip overlapping region area.
3. the joint of copper tip according to claim 2 and aluminum conductor, it is characterised in that described copper tip and aluminum conductor
The crimp region area of joint at least accounts for the 10% of aluminum conductor and copper tip overlapping region area.
4. the joint of copper tip and aluminum conductor according to claim 1, it is characterised in that described graded seal layer is by solder
Composition, the fusion penetration depth of described solder account for the 3%-100% of copper tip connector length.
5. the joint of copper tip according to claim 4 and aluminum conductor, it is characterised in that the fusion penetration depth of described solder
Account for the 30%-100% of copper tip connector length.
6. the joint of copper tip and aluminum conductor according to claim 2, it is characterised in that described graded seal layer is by solder
Composition, the fusion penetration depth of described solder account for the 5%-100% of whole crimp region length.
7. the joint of copper tip according to claim 6 and aluminum conductor, its feature exists, and the fusion penetration depth of described solder accounts for
The 35%-100% of whole crimp region length.
8. according to any copper tips of claim 4-7 and the joint of aluminum conductor, it is characterised in that the metal of described solder
Material is the metal or alloy that fusing point is not higher than aluminium.
9. the joint of copper tip and aluminum conductor according to claim 8, it is characterised in that the metal material of described solder contains
There is zinc.
10. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that described copper tip and aluminium is led
The joint of line, which also has, strengthens weld layer.
11. the joint of copper tip according to claim 10 and aluminum conductor, its feature exists, described reinforcing weld layer parcel
Aluminum conductor leads the end face of core.
12. the joint of copper tip according to claim 10 and aluminum conductor, its feature exists, the thickness of described reinforcing weld layer
Spend for 0-15mm.
13. the joint of copper tip according to claim 12 and aluminum conductor, its feature exists, the thickness for strengthening weld layer
For 1.5-5.5mm.
14. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that the material of described copper tip
For copper or copper alloy.
15. the joint of copper tip according to claim 1 and aluminum conductor, its feature exists, the connector shape of the copper tip
Shape is the hollow columnar of flat, arcuation or both ends open, and the side of hollow column for closure or does not close.
16. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that described copper tip surface is also
Contain coating.
17. the joint of copper tip according to claim 16 and aluminum conductor, its feature exists, and described thickness of coating is 3 μm
To 5000 μm.
18. the joint of copper tip according to claim 17 and aluminum conductor, its feature exists, and described thickness of coating is 5 μm
To 1000 μm.
19. the joint of copper tip according to claim 16 and aluminum conductor, its feature exists, and the coating passes through plating, electricity
The mode of magnetic weldering, electric arc spraying or pressure welding is attached on copper tip.
20. the joint of copper tip according to claim 16 and aluminum conductor, it is characterised in that the metal material of the coating
For chromium or evanohm, zinc or kirsite, tin or tin alloy, titanium or titanium alloy, zirconium or zircaloy, nickel or nickel alloy, silver or silver close
Gold, gold or billon in one kind.
21. the joint of copper tip according to claim 20 and aluminum conductor, it is characterised in that the metal material of the coating
For zinc or kirsite, tin or tin alloy, one kind in nickel or nickel alloy.
22. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that described aluminum conductor leads core
Material is aluminum or aluminum alloy.
23. the joint of copper tip according to claim 1 and aluminum conductor, it is characterised in that described aluminum conductor is solid
Wire or multicore cable.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201720642849.8U CN206962034U (en) | 2017-06-05 | 2017-06-05 | A kind of joint of copper tip and aluminum conductor |
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| CN201720642849.8U CN206962034U (en) | 2017-06-05 | 2017-06-05 | A kind of joint of copper tip and aluminum conductor |
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| CN107123866A (en) * | 2017-06-05 | 2017-09-01 | 吉林省中赢高科技有限公司 | A kind of joint and its plasma welding method of copper tip and aluminum conductor |
| JP2018059147A (en) * | 2016-10-04 | 2018-04-12 | Ｄｏｗａメタルテック株式会社 | Copper or copper alloy plate material and manufacturing method of the same and terminal |
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| JP2018059147A (en) * | 2016-10-04 | 2018-04-12 | Ｄｏｗａメタルテック株式会社 | Copper or copper alloy plate material and manufacturing method of the same and terminal |
| CN107123866A (en) * | 2017-06-05 | 2017-09-01 | 吉林省中赢高科技有限公司 | A kind of joint and its plasma welding method of copper tip and aluminum conductor |
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| CN110416759A (en) * | 2019-08-13 | 2019-11-05 | 广东电网有限责任公司 | A kind of the copper aluminum steel ear and wire bonding method of anti-couple-corrosion |
| WO2021027044A1 (en) * | 2019-08-13 | 2021-02-18 | 广东电网有限责任公司 | Copper aluminum cable lug for preventing electrochemical corrosion, and conducting wire connection method therefor |
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