WO2021104436A1 - 铝线缆与端子的连接结构及具有其的车辆 - Google Patents

铝线缆与端子的连接结构及具有其的车辆 Download PDF

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WO2021104436A1
WO2021104436A1 PCT/CN2020/132178 CN2020132178W WO2021104436A1 WO 2021104436 A1 WO2021104436 A1 WO 2021104436A1 CN 2020132178 W CN2020132178 W CN 2020132178W WO 2021104436 A1 WO2021104436 A1 WO 2021104436A1
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WO
WIPO (PCT)
Prior art keywords
cable
terminal
welding
aluminum
connection structure
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PCT/CN2020/132178
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English (en)
French (fr)
Inventor
肖海
全金龙
康海东
黄继业
袁野
Original Assignee
比亚迪股份有限公司
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Publication date
Application filed by 比亚迪股份有限公司 filed Critical 比亚迪股份有限公司
Priority to EP20892663.4A priority Critical patent/EP4068522B1/en
Priority to US17/777,854 priority patent/US20230030577A1/en
Priority to JP2022531058A priority patent/JP7465967B2/ja
Publication of WO2021104436A1 publication Critical patent/WO2021104436A1/zh

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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
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • 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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding

Definitions

  • the present application relates to the field of high-voltage connection technology, and in particular to a connection structure of an aluminum cable and a terminal and a vehicle having the connection structure of the aluminum cable and the terminal.
  • the aluminum material Due to its low strength, poor creep resistance, and surface contact with air, the aluminum material is easily oxidized. Therefore, when the high-voltage wiring harness is connected with aluminum cables and copper terminals, it is not suitable for cold compression welding, but for ultrasonic welding. Connect with copper terminals.
  • one purpose of the present application is to provide a connection structure between an aluminum cable and a terminal, and the connection mechanism between the aluminum cable and the terminal can take into account electrical conductivity, overcurrent capability, and mechanical strength.
  • the application also proposes a vehicle having the above-mentioned connection structure of the aluminum cable and the terminal.
  • An embodiment according to the first aspect of the present application proposes a connection structure between an aluminum cable and a terminal.
  • the connection structure between the aluminum cable and the terminal includes an aluminum cable, the aluminum cable includes a core, and the wire
  • the core is configured with a cable welding part; a terminal, the terminal is welded to the cable welding part; wherein the nominal cross-sectional area of the wire core is M, and the welding area of the cable welding part and the terminal S satisfies: 5*M ⁇ S ⁇ 6*M.
  • connection mechanism of the aluminum cable and the terminal according to the embodiment of the present application can take into account electrical conductivity, overcurrent capability, and mechanical strength.
  • the width of the cable welding portion corresponding to the nominal cross-sectional area M is W, then the length L of the cable welding portion satisfies: 5*M/W ⁇ L ⁇ 6*M/W.
  • the surface of the cable welding portion facing away from the terminal is configured as a corrugated surface, and the wave crests and troughs of the corrugated surface are arranged along the length direction of the cable welding portion.
  • the minimum thickness H of the cable welding part is the distance between the surface of the cable welding part facing the terminal and the wave trough, and the nominal cross-sectional area M
  • the width of the corresponding cable welding part is W
  • the minimum thickness H satisfies: 0.7*M/W ⁇ H ⁇ 0.8*M/W.
  • the maximum angle between the wave crest and the surface of the cable welding part facing the terminal is 30°-60°; the wave trough and the surface of the cable welding part facing the terminal are different The maximum angle ⁇ between them is 30° ⁇ 60°.
  • the aluminum cable further includes: an insulating sleeve, the insulating sleeve is sleeved on the outer side of the wire core, and the cable welding part extends from the insulating sleeve;
  • the terminal It includes a terminal welding part and a crimping part, the cable welding part is welded to the terminal welding part, and the crimping part is crimped to the insulating sleeve.
  • the thickness of the crimping portion is smaller than the thickness of the terminal welding portion.
  • the crimping portion includes a connecting portion and two crimping wings.
  • One end of the connecting portion is connected to the terminal welding portion, and the other end of the connecting portion is connected to the two crimping wings.
  • the crimping wings clamp the insulation sleeve and are staggered along the length direction of the insulation sleeve.
  • the length of the cable welding part is L
  • the length L1 of the connecting part satisfies: 0.7L ⁇ L1 ⁇ 0.9L.
  • a vehicle including the connection structure of the aluminum cable and the terminal according to the embodiment of the first aspect of the present application.
  • the vehicle according to the embodiment of the present application by using the connection structure of the aluminum cable and the terminal according to the embodiment of the first aspect of the present application, has the advantages of reliable electrical conductivity, strong overcurrent capability, and high mechanical strength.
  • Fig. 1 is a schematic processing diagram of a connection structure between an aluminum cable and a terminal according to an embodiment of the present application.
  • Fig. 2 is a perspective view of a connection structure between an aluminum cable and a terminal according to an embodiment of the present application.
  • Fig. 3 is a front view of a connection structure of an aluminum cable and a terminal according to an embodiment of the present application.
  • Fig. 4 is a side view of a terminal of a connection structure of an aluminum cable and a terminal according to another embodiment of the present application.
  • Fig. 5 is an expanded schematic view of a terminal of a connection structure of an aluminum cable and a terminal according to another embodiment of the present application.
  • connection structure of the aluminum cable and the terminal according to the embodiment of the present application will be described below with reference to the accompanying drawings.
  • connection structure between the aluminum cable and the terminal includes an aluminum cable 10 and a terminal 20.
  • the aluminum cable 10 includes a wire core 11, the wire core 11 is made of aluminum, and the wire core 11 is configured with a cable welding part 12.
  • the terminal 20 may be a copper terminal, and the terminal 20 is welded to the cable welding part 12, for example, ultrasonic welding.
  • the nominal cross-sectional area of the core 11 is M
  • the welding area S between the cable welding part 12 and the terminal 20 satisfies: 5*M ⁇ S ⁇ 6*M, which is understandably the nominal value of the core 11
  • the cross-sectional area M can be understood as the cross-sectional area of the core 11.
  • the ultrasonic welding process mainly includes three steps: positioning, laying out and welding.
  • the terminal 20 is first placed on the positioning block of the ultrasonic welding equipment, the left and right welding fixtures 1 are moved and pressed on the terminal 20, and the size between the left and right welding fixtures 1 is restricted to the size of the welding head 2 at the same time.
  • the core of the aluminum cable 10 is placed in the two welding jigs 1, the welding head 2 is moved down vertically, and the exposed core 11 of the aluminum cable 10 and the terminal 20 are welded.
  • the wire core 11 is generally circular, and the part welded by the welding head 2 is pressed into a flat shape, that is, the cable welding part 12, the nominal cross-sectional area of the wire core 11 in the embodiment of the present application M means the cross-sectional area of the circular part.
  • connection structure of the aluminum cable and the terminal since the quality of the aluminum cable 10 is 2/3 of the quality of the copper cable, and the cost of the aluminum cable 10 is 2/3 of the cost of the copper cable Therefore, the use of the connection structure of the aluminum cable and the terminal achieves the purpose of cost reduction and light weight. Further, by limiting the welding area between the aluminum cable 10 and the terminal 20, that is, 5*M ⁇ S ⁇ 6*M, on the one hand, it can avoid that the welding area is too small, so that the welding energy is too concentrated and high temperature is generated, which leads to excessive welding. This in turn leads to insufficient mechanical strength after welding, and ultimately reduces the reliability of the aluminum cable 10 in use.
  • the cable welding part 12 and the terminal 20 The welding area S is limited to 5*M ⁇ S ⁇ 6*M, which can not only take into account the electrical conductivity, flow capacity and mechanical strength, but also control the welding difficulty coefficient and welding process cost.
  • the width of the cable welding portion 12 corresponding to the nominal cross-sectional area M is W, and the length L of the cable welding portion 12 satisfies: 5*M/W ⁇ L ⁇ 6*M/W.
  • the width of the cable welding portion 12 is correspondingly fixed.
  • the length L of the cable welding part 12 is set to 5*M/W ⁇ L ⁇ 6*M/W, so as to ensure that after welding with the terminal 20, it has a good new type of electric conduction, overcurrent capability and mechanical strength.
  • the length L of the cable welding part 12 is limited, that is, 5*M/W ⁇ L ⁇ 6*M/W.
  • it can prevent the length from being too small, which will lead to the welding area being too small, so that the welding energy is too concentrated and high temperature , Resulting in excessive welding, which in turn leads to insufficient mechanical strength after welding, and ultimately reduces the reliability of the aluminum cable 10 in use;
  • the length L of the cable welding portion 12 is too long, the length of the terminal 20 is increased , which not only leads to a new structural design of the connector using the connection structure of the aluminum cable and the terminal, which increases the design cost, but also leads to an increase in the material cost of the terminal.
  • the nominal cross-sectional area M of the core 11 is 50 mm 2
  • the corresponding width W of the cable welding part 12 is 16 mm
  • the length L of the cable welding part 12 satisfies: 15.6 mm ⁇ L ⁇ 18.8 mm.
  • the nominal cross-sectional area M of the wire core 11 is 70 mm 2
  • the corresponding width W of the cable welding part 12 is 21 mm
  • the length L of the cable welding part 12 satisfies: 16.7 mm ⁇ L ⁇ 20 mm.
  • the surface of the cable welding portion 12 facing away from the terminal 20 is configured as a corrugated surface 14, and the wave crests and troughs of the corrugated surface 14 are arranged along the length direction of the cable welding portion 12. cloth.
  • the minimum thickness H of the cable welding portion 12 is the distance between the surface of the cable welding portion 12 facing the terminal 20 and the wave trough, and the cable welding corresponding to the nominal cross-sectional area M
  • the width of the part 12 is W
  • the minimum thickness H of the cable welding part 12 satisfies: 0.7*M/W ⁇ H ⁇ 0.8*M/W.
  • the minimum thickness H of the cable welding portion 12 satisfies the compression ratio of 70% to 80%.
  • the minimum thickness H is less than 70% of the compression ratio, welding wire breakage is likely to occur, so that the conductivity of the aluminum cable 10 is reduced; when the minimum thickness H is higher than the compression ratio of 80%, the risk of welding mechanical tensile strength not meeting the standard is likely to occur. Further, when the minimum thickness H of the cable welding portion 12 satisfies the compression ratio of 70%-80%, it has a better welding appearance.
  • the nominal cross-sectional area of the core 11 is 50mm 2
  • the width W of the corresponding cable welding part 12 is 16mm
  • the minimum thickness H of the cable welding part 12 satisfies: 2.2mm ⁇ H ⁇ 2.5mm, Therefore, the welding compression ratio of the aluminum cable 10 satisfies 70%-80%.
  • the corrugated surface 14 adopts large and small welding patterns.
  • the number of wave crests and troughs of the corrugated surface 14 are both 2, that is, two.
  • One wave crest and two wave troughs are evenly distributed on the corrugated surface 14 of the cable welding part 12.
  • the maximum angle between the wave crest and the surface of the cable soldering portion 12 facing the terminal 20 is 30°-60°, that is, the tangent of the portion of the wave crest closest to the trough and the soldering surface of the cable soldering portion 12 The acute angle between them is 30° ⁇ 60°.
  • the maximum angle ⁇ between the wave trough and the surface of the cable welding part 12 facing the terminal 20 is 30°-60°, that is, the tangent line of the part of the wave trough closest to the wave peak and the welding surface of the cable welding part 12
  • the acute angle is 30° ⁇ 60°.
  • the welding surface of the aluminum cable 10 can be guaranteed to have a smooth transition without causing damage to the surface of the wire core 11. The damage makes the effective welding and fusion area between the cable welding part 12 and the terminal 20 larger.
  • the aluminum cable 10 further includes an insulating sleeve 13, the insulating sleeve 13 is sleeved on the outside of the core 11, the cable welding portion 12 extends from the insulating sleeve 13, and the terminal 20 includes a terminal welding portion 21 and the crimping part 22, the cable welding part 12 is welded to the terminal welding part 21, and the crimping part 22 is crimped to the insulating sleeve 13.
  • the crimping portion 22 includes a connecting portion 24 and two crimping wings 23, one end of the connecting portion 24 is connected to the terminal welding portion 21, and the other end of the connecting portion 24 is connected to the two crimping wings 23,
  • the two crimping wings 23 clamp the insulating sleeve 13, and the two crimping wings 23 are staggered along the length of the insulating sleeve 13.
  • the crimping portion 22 has two crimping wings 23 staggered, and the insulating sleeve 13 of the aluminum cable 10 is inserted into the channel formed by the two crimping wings 23, and the two crimping wings are connected by a crimping jig.
  • the wing 23 is crimped to the outer surface of the insulating sleeve 13 of the aluminum cable 10, so that the crimping wing 23 and the insulating sleeve 13 of the aluminum cable 10 are fixedly connected, and the crimping wing 23 can reduce the mechanical stress acting on the welding area. Transfer to the insulating sleeve 13 of the aluminum cable 10, which can effectively prevent damage to the welding part caused by pulling the aluminum cable 10.
  • the thickness of the crimping portion 22 is smaller than the thickness of the terminal welding portion 21, and in the radial direction of the aluminum cable 10, the crimping portion 22 is away from the aluminum cable 10 with respect to the terminal welding portion 21.
  • the directions are staggered.
  • the upper surface of the crimping portion 22 and the lower surface of the terminal welding portion 21 are located on the same plane, so that the height difference between the core 11 and the insulating sleeve 13 can be adapted to avoid the core 11 and the cable.
  • the joint of the welded portion 12 is excessively deformed.
  • the length of the cable welding portion 12 is L, and the length L1 of the connecting portion 24 satisfies: 0.7L ⁇ L1 ⁇ 0.9L, which can prevent the crimping wing 23 from damaging the wire when crimping The connection between the core 11 and the cable welding part 12.
  • the vehicle includes the connection structure of the aluminum cable and the terminal according to the above-mentioned embodiment of the present application.
  • the vehicle according to the embodiment of the present application by using the connection structure of the aluminum cable and the terminal according to the foregoing embodiment of the present application, has the advantages of reliable electrical conductivity, strong overcurrent capability, and high mechanical strength.

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Abstract

一种铝线缆与端子的连接结构，所述铝线缆与端子的连接结构包括：铝线缆(10)，所述铝线缆(10)包括线芯(11)，所述线芯(11)构造有线缆焊接部(12)；端子(20)，所述端子(20)与所述线缆焊接部(12)焊接；其中，所述线芯(11)的标称横截面积为M，所述线缆焊接部(12)与所述端子(20)的焊接面积S满足：5*M≤S≤6*M。

Description

铝线缆与端子的连接结构及具有其的车辆
相关申请的交叉引用
本申请要求申请日为2019年11月28日、申请号为201922114520.6、专利申请名称为“铝线缆与端子的连接结构及具有其的车辆”的优先权。
技术领域
本申请涉及高压连接技术领域，尤其是涉及一种铝线缆与端子的连接结构和具有所述铝线缆与端子的连接结构的车辆。
背景技术
铝材质由于本身强度低，抗蠕变性差，表面接触空气易氧化等缺陷，因此高压线束使用铝电缆和铜端子连接时，不适合采用冷压压接的方式连接，而适合采用超声波焊接的方式与铜端子连接。
但是，现有的铝线缆与端子超声波焊接后，无法兼顾电传导性能、过流能力和机械强度，存在改进的需求。
发明内容
本申请旨在至少解决现有技术中存在的技术问题之一。为此，本申请的一个目的在于提出一种铝线缆与端子的连接结构，该铝线缆与端子的连接机构能够兼顾电传导性能、过流能力和机械强度。
本申请还提出一种具有上述铝线缆与端子的连接结构的车辆。
根据本申请的第一方面的实施例提出一种铝线缆与端子的连接结构，所述铝线缆与端子的连接结构包括：铝线缆，所述铝线缆包括线芯，所述线芯构造有线缆焊接部；端子，所述端子与所述线缆焊接部焊接；其中，所述线芯的标称横截面积为M，所述线缆焊接部与所述端子的焊接面积S满足：5*M≤S≤6*M。
根据本申请实施例的铝线缆与端子的连接机构能够兼顾电传导性能、过流能力和机械强度。
根据本申请的一些具体实施例，与所述标称横截面积M对应的所述线缆焊接部的宽度为W，则所述线缆焊接部的长度L满足：5*M/W≤L≤6*M/W。
根据本申请的一些具体实施例，所述线缆焊接部的背向所述端子的表面构造成波纹面， 所述波纹面的波峰和波谷沿所述线缆焊接部的长度方向排布。
根据本申请的一些具体实施例，所述线缆焊接部的最小厚度H为所述线缆焊接部朝向所述端子的表面与所述波谷之间的距离，与所述标称横截面积M对应的线缆焊接部的宽度为W，所述最小厚度H满足：0.7*M/W≤H≤0.8*M/W。
进一步地，所述波峰与所述线缆焊接部的朝向所述端子的表面之间的最大角度为30°～60°；所述波谷与所述线缆焊接部的朝向所述端子的表面之间的最大角度β为30°～60°。
根据本申请的一些具体实施例，所述铝线缆还包括：绝缘套，所述绝缘套套设于所述线芯的外侧，所述线缆焊接部从所述绝缘套伸出；所述端子包括端子焊接部和压接部，所述线缆焊接部与所述端子焊接部焊接，所述压接部与所述绝缘套压接。
进一步地，所述压接部的厚度小于所述端子焊接部的厚度。
进一步地，所述压接部包括连接部和两个压接翼，所述连接部一端与所述端子焊接部连接，所述连接部另一端与所述两个压接翼连接，两个所述压接翼夹持所述绝缘套且沿所述绝缘套的长度方向错开设置。
进一步地，所述线缆焊接部的长度为L，所述连接部的长度L1满足：0.7L≤L1≤0.9L。
根据本申请的第二方面的实施例提出一种车辆，所述车辆包括根据本申请的第一方面的实施例所述的铝线缆与端子的连接结构。
根据本申请实施例的车辆，通过利用根据本申请的第一方面的实施例所述的铝线缆与端子的连接结构，具有电传导性能可靠、过流能力强和机械强度高等优点。
本申请的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本申请的实践了解到。
附图说明
本申请的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1是根据本申请实施例的铝线缆与端子的连接结构的加工示意图。
图2是根据本申请实施例的铝线缆与端子的连接结构的立体图。
图3是根据本申请实施例的铝线缆与端子的连接结构的正视图。
图4是根据本申请另一个实施例的铝线缆与端子的连接结构的端子的侧视图。
图5是根据本申请另一个实施例的铝线缆与端子的连接结构的端子的展开示意图。
附图标记：
铝线缆10、线芯11、线缆焊接部12、绝缘套13、波纹面14、端子20、端子焊接部21、压接部22、压接翼23、连接部24、 焊接夹具1、焊头2。
具体实施方式
下面详细描述本申请的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本申请，而不能理解为对本申请的限制。
在本申请的描述中，需要理解的是，术语“长度”、“宽度”、“厚度”、“内”、“外”、等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。
下面参考附图描述根据本申请实施例的铝线缆与端子的连接结构。
如图2-图5所示，根据本申请实施例的铝线缆与端子的连接结构包括铝线缆10和端子20。
铝线缆10包括线芯11，线芯11为铝材质，线芯11构造有线缆焊接部12。端子20可以为铜端子，端子20与线缆焊接部12焊接，例如超声波焊接。
其中，线芯11的标称横截面积为M，线缆焊接部12与端子20的焊接面积S满足：5*M≤S≤6*M，这里可以理解地是，线芯11的标称横截面积为M可以理解为线芯11的横截面积。
下面举例描述根据本申请实施例的铝线缆10和端子20的焊接过程。
如图1所示，超声波焊接加工过程主要包括定位、放线、焊接三个步骤。
先将端子20放在超声波焊接设备定位块上，左右两块焊接夹具1移动压在端子20上，同时限制左右两块焊接夹具1之间的尺寸为焊头2尺寸。将铝线缆10的线芯放在两块焊接夹具1中，焊头2垂直下移，对铝线缆10的裸露在外的线芯11与端子20进行焊接。
其中，需要理解地是，线芯11通常为圆形，被焊头2焊接的部分被压成扁平状，即线缆焊接部12，本申请实施例中的线芯11的标称横截面积为M是指圆形部分的横截面积。
根据本申请实施例的铝线缆与端子的连接结构，由于铝线缆10的质量是铜线缆的质量的2/3,且铝线缆10的成本是铜线缆的成本的2/3，所以，采用铝线缆与端子的连接结构，实现了成本降低和轻量化的目的。进一步地，通过限定铝线缆10与端子20的焊接面积，即5*M≤S≤6*M，一方面能够避免焊接面积过小，以致焊接能量过于集中而产生高温，从而导致过度焊接，进而导致焊接后的机械强度不足，最终降低铝线缆10使用时的可靠性；另一方面当焊接面积过小时，则导致焊接面积每mm 2允许通过的电流过大，则会导致焊接部位容易被烧坏，从而导致焊接部位的使用寿命短；此外，当焊接面积过大时，则导致焊 接面积每mm 2允许通过的电流过小，进而降低了铝线缆的电传导性能，对此，本案通过5*M≤S≤6*M限定焊接面积，进而致使各种规格的铝线缆能够兼顾电传导性能、过流能力和机械强度。
下面以标称横截面积为50mm 2的线芯为例，测试铝线缆的过流能力和焊接机械强度，测试结果如下表所示：
S/M 过流能力 焊接机械强度
4.5 180A 2500N
5 200A 3000N
5.5 210A 3200N
6 200A 3000N
6.5 200A 3000N
通过上表可知，S/M的数值从4.5变化为5.5时，过流能力和焊接机械强度均处于上升趋势，而S/M的数值从5.5变化为6.5时，过流能力和焊接机械强度均处于下降趋势，因此，在5-6之间时，铝线缆具有最优的过流能力和焊接机械强度。
与此同时，当S/M的数值超过6时，过流能力和焊接机械强度的变化变缓。但是，当焊接面积变大时，焊接部位的延展，焊接部位的压力的控制等各种原因，则会导致焊接工艺成本增加，以及焊接难度系数增加，因此，将线缆焊接部12与端子20的焊接面积S限定为5*M≤S≤6*M，既能够兼顾电传导性能、过流能力和机械强度，也能控制焊接难度系数和焊接工艺成本。
在本申请的一些具体实施例中，与所述标称横截面积M对应的线缆焊接部12的宽度为W，则线缆焊接部12的长度L满足：5*M/W≤L≤6*M/W。换言之，对于不同标称横截面积的线芯11，其线缆焊接部12的宽度是对应固定的，例如可参照USCAR-38(美国汽车工程师协会超声波焊接标准)，在此基础上，将线缆焊接部12的长度L设置为5*M/W≤L≤6*M/W，从而能够保证与端子20焊接后，具有良好的电传导新型、过流能力和机械强度。
本案通过限定线缆焊接部12的长度L，即5*M/W≤L≤6*M/W，一方面能够避免长度过小，进而导致焊接面积过小，以致焊接能量过于集中而产生高温，从而导致过度焊接，进而导致焊接后的机械强度不足，最终降低铝线缆10使用时的可靠性；另一方面当线缆焊接部12的长度L过长时，则导致端子20的长度增加，既导致应用该铝线缆与端子的连接结构的连接器重新进行结构设计，从而增加设计成本，也导致端子的材料成本增加。
为了更加详细说明本申请的技术方案，以如下两种线缆进行示例性说明。
例如，线芯11的标称横截面积为M为50mm 2，对应的线缆焊接部12的宽度W为16mm，线缆焊接部12的长度L满足：15.6mm≤L≤18.8mm。
进一步地，线芯11的标称横截面积为M为70mm 2，对应的线缆焊接部12的宽度W为21mm，线缆焊接部12的长度L满足：16.7mm≤L≤20mm。
在本申请的一些具体示例中，如图2所示，线缆焊接部12的背向端子20的表面构造成波纹面14，波纹面14的波峰和波谷沿线缆焊接部12的长度方向排布。
其中，如图2所示，线缆焊接部12的最小厚度H为线缆焊接部12的朝向端子20的表面与所述波谷之间的距离，与标称横截面积M对应的线缆焊接部12的宽度为W，线缆焊接部12的最小厚度H满足：0.7*M/W≤H≤0.8*M/W。
由此，线缆焊接部12的最小厚度H满足压缩比70％-80％。当最小厚度H低于压缩比70％时，易于出现焊接断丝，以致铝线缆10的导电能力降低；当最小厚度H高于压缩比80％时，易于出现焊接机械拉力强度不达标风险。进一步地，线缆焊接部12的最小厚度H满足压缩比70％-80％时，具备较好的焊接外观。
为了更加详细说明本申请的技术方案，以如下一种线缆进行示例性说明。
例如，线芯11的标称横截面积为M为50mm 2，对应的线缆焊接部12的宽度W为16mm，线缆焊接部12的最小厚度H满足：2.2mm≤H≤2.5mm，由此，铝线缆10的焊接压缩比满足70％-80％。
进一步地，由于铝导体材质强度较低，为了避免波纹过于密集而造成焊接断丝，波纹面14采用大而少的焊接纹路，例如，波纹面14的波峰和波谷的数量均为2，即两个波峰和两个波谷且均匀分布在线缆焊接部12的波纹面14。
更进一步地，所述波峰与线缆焊接部12的朝向端子20的表面之间的最大角度为30°～60°，即波峰最邻近波谷的部分的切线，与线缆焊接部12的焊接面之间的锐角为30°～60°。
所述波谷与线缆焊接部12的朝向端子20的表面之间的最大角度β为30°～60°，即波谷最邻近波峰的部分的切线，与线缆焊接部12的焊接面之间的锐角为30°～60°。
由于新能源汽车采用的高压铝电缆的线芯抗拉强度通常为70MPa～120MPa,，通过设置波峰和波谷的角度，能够保证铝线缆10的焊接表面平缓过渡，不会对线芯11表面造成破坏，使得线缆焊接部12与端子20之间的有效焊接融合面积更大。
在本申请的一些具体实施例中，铝线缆10还包括绝缘套13，绝缘套13套设于线芯11的外侧，线缆焊接部12从绝缘套13伸出，端子20包括端子焊接部21和压接部22，线缆焊接部12与端子焊接部21焊接，压接部22与绝缘套13压接。
具体地，如图5所示，压接部22包括连接部24和两个压接翼23，连接部24一端与端子焊接部21连接，连接部24另一端与两个压接翼23连接，两个压接翼23夹持绝缘套13， 且两个压接翼23沿绝缘套13的长度方向错开设置。
由此，压接部22具有错落设置的两个压接翼23，铝线缆10的绝缘套13穿设于两个压接翼23形成的通道中，通过压接治具将两个压接翼23压接至铝线缆10的绝缘套13的外表面上，从而压接翼23与铝线缆10的绝缘套13两者固定连接，压接翼23能够将作用在焊接区域的机械应力转移至铝线缆10的绝缘套13上，这样可以有效防止因扯动铝线缆10而导致焊接部分的损坏。
进一步地，如图4所示，压接部22的厚度小于端子焊接部21的厚度，且在铝线缆10的径向上，压接部22相对于端子焊接部21向远离铝线缆10的方向错开设置，例如，压接部22的上表面与端子焊接部21的下表面位于同一平面，这样可以适配线芯11与绝缘套13的过渡区域的高度差，避免线芯11和线缆焊接部12的连接处过度变形。
更进一步地，如图5所示，线缆焊接部12的长度为L，连接部24的长度L1满足：0.7L≤L1≤0.9L，由此能够避免压接翼23压接时不损伤线芯11与线缆焊接部12的连接处。
下面描述根据本申请实用实施例的车辆，所述车辆包括根据本申请上述实施例的铝线缆与端子的连接结构。
根据本申请实施例的车辆，通过利用根据本申请上述实施例的铝线缆与端子的连接结构，具有电传导性能可靠、过流能力强和机械强度高等优点。
根据本申请实施例的车辆的其他构成以及操作对于本领域普通技术人员而言都是已知的，这里不再详细描述。
在本说明书的描述中，参考术语“具体实施例”、“具体示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本申请的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。
尽管已经示出和描述了本申请的实施例，本领域的普通技术人员可以理解：在不脱离本申请的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本申请的范围由权利要求及其等同物限定。

Claims (10)

  1. 一种铝线缆与端子的连接结构，其特征在于，包括：
    铝线缆，所述铝线缆包括线芯，所述线芯构造有线缆焊接部；
    端子，所述端子与所述线缆焊接部焊接；
    其中，所述线芯的标称横截面积为M，所述线缆焊接部与所述端子的焊接面积S满足：5*M≤S≤6*M。
  2. 根据权利要求1所述的铝线缆与端子的连接结构，其特征在于，与所述标称横截面积M对应的所述线缆焊接部的宽度为W，则所述线缆焊接部的长度L满足：5*M/W≤L≤6*M/W。
  3. 根据权利要求1所述的铝线缆与端子的连接结构，其特征在于，所述线缆焊接部背向所述端子的表面构造成波纹面，所述波纹面的波峰和波谷沿所述线缆焊接部的长度方向排布。
  4. 根据权利要求3所述的铝线缆与端子的连接结构，其特征在于，所述线缆焊接部的最小厚度H为所述线缆焊接部朝向所述端子的表面与所述波谷之间的距离，与所述标称横截面积M对应的线缆焊接部的宽度为W，所述最小厚度H满足：0.7*M/W≤H≤0.8*M/W。
  5. 根据权利要求3或4所述的铝线缆与端子的连接结构，其特征在于，
    所述波峰与所述线缆焊接部朝向所述端子的表面之间的最大角度为30°～60°；
    所述波谷与所述线缆焊接部朝向所述端子的表面之间的最大角度β为30°～60°。
  6. 根据权利要求1-5中任一项所述的铝线缆与端子的连接结构，其特征在于，所述铝线缆还包括：
    绝缘套，所述绝缘套套设于所述线芯的外侧，所述线缆焊接部从所述绝缘套伸出；
    所述端子包括端子焊接部和压接部，所述线缆焊接部与所述端子焊接部焊接，所述压接部与所述绝缘套压接。
  7. 根据权利要求6所述的铝线缆与端子的连接结构，其特征在于，所述压接部的厚度小于所述端子焊接部的厚度。
  8. 根据权利要求6或7所述的铝线缆与端子的连接结构，其特征在于，所述压接部包括连接部和两个压接翼，所述连接部一端与所述端子焊接部连接，所述连接部另一端与所述两个压接翼连接，两个所述压接翼夹持所述绝缘套且沿所述绝缘套的长度方向错开设置。
  9. 根据权利要求8所述的铝线缆与端子的连接结构，其特征在于，所述线缆焊接部的长度为L，所述连接部的长度L1满足：0.7L≤L1≤0.9L。
  10. 一种车辆，其特征在于，包括根据权利要求1-9中任一项所述的铝线缆与端子的连接结构。
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