WO2021197414A1 - 一种电能传输接头及其制备方法 - Google Patents
一种电能传输接头及其制备方法 Download PDFInfo
- Publication number
- WO2021197414A1 WO2021197414A1 PCT/CN2021/084901 CN2021084901W WO2021197414A1 WO 2021197414 A1 WO2021197414 A1 WO 2021197414A1 CN 2021084901 W CN2021084901 W CN 2021084901W WO 2021197414 A1 WO2021197414 A1 WO 2021197414A1
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- WO
- WIPO (PCT)
- Prior art keywords
- aluminum
- power transmission
- copper
- cavity
- welding
- Prior art date
Links
- 230000005540 biological transmission Effects 0.000 title claims abstract description 191
- 238000002360 preparation method Methods 0.000 title claims abstract description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 167
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 165
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 51
- 238000002788 crimping Methods 0.000 claims abstract description 29
- 229910052802 copper Inorganic materials 0.000 claims abstract description 28
- 239000010949 copper Substances 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims abstract description 16
- 239000004020 conductor Substances 0.000 claims abstract 4
- 238000003466 welding Methods 0.000 claims description 53
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims description 46
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- 230000007704 transition Effects 0.000 claims description 24
- 238000009413 insulation Methods 0.000 claims description 14
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 6
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- 230000008901 benefit Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 6
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- 239000002184 metal Substances 0.000 description 4
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- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 3
- 229910052793 cadmium Inorganic materials 0.000 description 3
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 3
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
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- 210000001503 joint Anatomy 0.000 description 3
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- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- 229910000914 Mn alloy Inorganic materials 0.000 description 2
- 229910000990 Ni alloy Inorganic materials 0.000 description 2
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
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Images
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
- 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
-
- 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
- H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
-
- 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
- H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
-
- 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
-
- 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
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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
- H01R43/02—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
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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
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
- H01R43/0482—Crimping apparatus or processes combined with contact member manufacturing mechanism
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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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- 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
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
-
- 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
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
Definitions
- the invention relates to the technical field of electrical connection, in particular to an electric energy transmission joint and a preparation method thereof.
- the technical problem solved by the present invention is to provide a power transmission joint, which uses a copper power transmission part with a through hole to connect with the power transmission aluminum part, which further reduces the weight of the power transmission joint.
- the manufacturing cost of the power transmission joint is obviously reduced.
- a power transmission joint includes a copper power transmission part, an aluminum power transmission part, and an aluminum wire.
- the copper power transmission part includes a fixing part for connecting an electrical device and a connecting part for connecting the aluminum power transmission part,
- a first through hole is arranged inside the power transmission aluminum piece, a second through hole is arranged inside the connecting piece, and the aluminum conductive core exposed after the insulating layer is stripped at the front end of the aluminum wire extends into the first through hole Inside the cavity formed by connecting with the second through hole, and the electric power transmission aluminum piece is connected to the aluminum wire by crimping.
- the invention also discloses a preparation method of the electric energy transmission joint, which comprises the following steps:
- Welding step connect the connecting piece of the power transmission copper part and the power transmission aluminum part by welding;
- the aluminum wire crimping step the exposed aluminum core is extended into the cavity after the insulation layer at the front end of the aluminum wire is stripped, and then the aluminum wire and the aluminum part for power transmission are crimped together.
- the present invention has the following beneficial effects:
- a second through hole is arranged inside the connecting piece of the power transmission copper part, which significantly reduces the weight of the power transmission copper part and saves production costs, and the power transmission copper part can be stamped with copper tube materials Forming, production is quick and simple. Moreover, due to the relatively small volume of the power transmission copper parts and the power transmission aluminum parts, the automatic loading and unloading of the power transmission copper parts and the power transmission aluminum parts can be realized, and the connecting parts and the electric energy can be directly removed after welding. Transmission of flash generated during welding of aluminum parts saves processing time and greatly improves assembly efficiency.
- the cavity is filled with sealant or solder.
- sealant or solder discharges the air in the cavity to prevent the air and water from corroding the connecting piece and the power transmission aluminum part; on the other hand, because the material of the power transmission aluminum part is soft, its When crimping aluminum wires, the mechanical properties of the power transmission joint may be insufficient, and the solder can connect the connecting piece, the power transmission aluminum piece, and the aluminum conductive core together, thereby strengthening the electrical energy.
- the connection strength of the transmission joint to the aluminum wire increases the contact area between the aluminum guide core and the connecting member and the power transmission aluminum member, and further improves the electrical performance of the power transmission joint.
- a transition connection device is also provided between the aluminum guide core and the inner wall of the cavity, and at least part of the surface of the transition connection device is provided with protrusions, and the protrusions are used to pierce the surface of the aluminum guide core And the oxide layer on the surface of the cavity, thereby reducing the resistance between the aluminum wire and the power transmission aluminum part through the protrusion, and increasing the crimping area of the aluminum wire and the power transmission aluminum part
- the electrical conductivity of the crimping area reduces the burning accident caused by the heat caused by the increase in resistance in the crimping area.
- the crimping length of the aluminum wire occupies at least 5% of the length of the power transmission aluminum part, which further increases the connection strength of the power transmission aluminum part and increases the electrical conductivity of the power transmission aluminum part.
- the inner diameter of the power transmission aluminum part is 1 to 3 times the diameter of the circumscribed circle of the aluminum wire insulation layer. It not only prevents the aluminum wire from being unable to be inserted into the power transmission aluminum piece, but also ensures that the power transmission aluminum piece and the aluminum wire will not be broken due to excessive deformation during crimping.
- the transitional connection device is a hollow cylinder at least partially sleeved on the aluminum guide core.
- the installation of the transitional connection device is automated in mass production, which improves production efficiency; on the other hand, the transition The connecting device can pre-shrink the loose aluminum guide core, so that the aluminum guide core can be inserted into the cavity more conveniently, and avoid part of the core wire of the aluminum guide core generated in the production process from being in the cavity. In other cases, the product quality of the power transmission joint is improved.
- a copper-aluminum transition layer with copper and aluminum atoms infiltrating or combining with each other is formed between the connecting member and the power transmission aluminum member.
- the copper-aluminum transition layer can effectively reduce the electrochemical corrosion between copper and aluminum.
- the service life of the power transmission joint is prolonged by about 20%; moreover, the connection piece and the power transmission aluminum piece are connected by friction welding, which can increase the production efficiency by about 26%, reduce the number of labor, and avoid errors caused by fatigue. Operation, reduce safety accidents and improve product quality.
- Fig. 1 is a schematic diagram of the structure of the power transmission joint according to the present invention.
- the present invention discloses a power transmission joint, which includes a power transmission copper piece, a power transmission aluminum piece 9 and an aluminum wire 3.
- the power transmission copper piece includes a fixing piece 1 for connecting electrical devices and a A second through hole is arranged inside the connecting piece 2 that is connected to the aluminum electric power transmission piece 9, and a first through hole is arranged inside the aluminum electric power transmission piece 9, and the front end of the aluminum wire 3 is stripped. After removing the insulating layer 5, it extends into the cavity formed by the connection of the first through hole and the second through hole, and the power transmission aluminum member 9 is connected to the aluminum wire 3 by crimping.
- the connecting member 2 Since the connecting member 2 is provided with a second through hole inside, the weight of the power transmission copper member is greatly reduced, and the production cost is saved; moreover, when the power transmission joint is connected, first the power transmission copper member The connecting piece 2 is connected to the power transmission aluminum piece 9, and then the front end of the aluminum wire 3 is stripped of the insulating layer 5 and then extended into the cavity formed by the connection of the first through hole and the second through hole, and finally the power transmission aluminum piece 9 It is formed by crimping with the aluminum wire 3, and the connection method is simple, which can realize the automation of the assembly of the power transmission joint, and greatly improve the assembly efficiency.
- the automatic loading and unloading of the power transmission copper part and the power transmission aluminum part 9 can be realized; moreover, the connection can be cut directly after welding
- the flash produced during welding of the part 2 and the power transmission aluminum part 9 makes the power transmission joint without the aluminum wire 3 when the flash is removed, which not only saves processing time and improves the efficiency of assembly, but also avoids The impact of flash cutting with the aluminum wire 3 on the power transmission joint improves the yield of the power transmission joint.
- the power transmission copper part is formed by stamping and forming a tubular copper tube, and the stamped and formed power transmission copper part includes a fixing part 1 and a connecting part 2, and the inside of the connecting part 2 A second through hole is provided; moreover, the position where the front end of the aluminum wire 3 extends into the cavity may be located in the first through hole or in the second through hole.
- the surface of the fixing member 1 and the connecting member 2 is provided with a plating layer, and the material of the plating layer contains at least nickel, cadmium, zirconium, chromium, cobalt, manganese, aluminum, tin, titanium, zinc, copper, and silver Or one of gold, so as to reduce the oxidation corrosion rate of the power transmission copper parts through the plating layer, and prolong the service life of the power transmission copper parts.
- the inner diameter of the power transmission aluminum member 9 is 1 to 3 times the diameter of the circumscribed circle of the aluminum wire insulation layer 5. On the one hand, it can facilitate the front end of the aluminum wire 3 to strip the insulating layer 5 and then extend into the cavity formed by the connection of the first through hole and the second through hole; on the other hand, due to the power transmission aluminum
- the member 9 is connected to the aluminum wire 3 by crimping. Therefore, if the inner diameter of the power transmission aluminum member 9 is greater than 3 times the diameter of the circumscribed circle of the aluminum wire insulation layer 5, the power transmission aluminum member 9 It is necessary to compress a larger ratio to ensure crimp connection to the aluminum wire 3, which may easily cause the power transmission aluminum piece 9 to break.
- Table 1 The influence of the ratio of the inner diameter of the power transmission aluminum part to the diameter of the circumscribed circle of the aluminum wire insulation layer on the performance of the power transmission joint
- a sealant or solder 7 is filled between the aluminum guide core 4 exposed after the insulating layer 5 is stripped off the front end of the aluminum wire 3 and the cavity.
- the sealant or solder 7 is discharged from the cavity. Air, to prevent the air and water in the cavity from corroding the connecting piece 2 and the power transmission aluminum piece 9; This may cause insufficient mechanical properties of the power transmission joint, and the sealant or solder 7 connects the connecting piece 2, the power transmission aluminum piece 9 and the aluminum guide core 4 together, which strengthens the joints.
- the solder 7 increases the contact area between the aluminum guide core 4 and the connecting member 2 and the power transmission aluminum member 9 to further improve the electrical performance of the power transmission joint.
- the material of the solder contains at least nickel and nickel alloys, cadmium and cadmium alloys, zirconium and zirconium alloys, chromium and chromium alloys, cobalt and cobalt alloys, manganese and manganese alloys, tin and tin One of alloys, titanium and titanium alloys, zinc and zinc alloys, copper and copper alloys, silver and silver alloys, or gold and gold alloys.
- the material of the solder is a metal or alloy with a melting point not higher than aluminum.
- the sealant 7 since the sealant 7 has good ductility and tightness, when the sealant 7 is filled between the aluminum guide core 4 and the cavity, the sealant 7 can hold the aluminum guide core The area between 4 and the cavity is sealed and protected, so that the aluminum guide core 4 and the cavity are greatly reduced from corrosion by moisture and salt spray, thereby prolonging the service life of the power transmission joint.
- the sealant 7 includes, but is not limited to, conductive adhesive, rubber-based sealant, resin-based sealant, or oil-based sealant.
- a transitional connecting device 8 is further provided between the aluminum guide core 4 and the inner wall of the cavity, and at least part of the surface of the transitional connecting device 8 is provided with protrusions, the protrusions being used to puncture The oxide layer on the surface of the aluminum guide core 4 and the inner wall surface of the cavity is broken.
- the material of the transition connection device 8 contains at least nickel and nickel alloys, cadmium and cadmium alloys, zirconium and zirconium alloys, chromium and chromium alloys, cobalt and cobalt alloys, manganese and manganese alloys, One of tin and tin alloys, titanium and titanium alloys, zinc and zinc alloys, copper and copper alloys, silver and silver alloys, or gold and gold alloys.
- the protrusion increases the contact area between the aluminum guide core 4, the transition connection device 8 and the power transmission aluminum part 9, and increases the aluminum wire 3 and the transition connection device 8. , And the friction between the transitional connection device 8 and the power transmission aluminum part 9, thereby preventing the aluminum wire 3 from detaching from the power transmission aluminum part 9, so that the power transmission joint has better mechanical properties.
- the protrusions also increase the conductive bumps of the aluminum guide core 4, which enhances the conductive effect, and at the same time destroys the oxide layer on the surface of the aluminum guide core 4 and the inner wall surface of the cavity, so that The aluminum guide core 4 is in direct contact with the transitional connection device 8 and the transitional connection device 8 is in direct contact with the conductive part of the cavity, thereby improving the electrical performance of the power transmission joint.
- the protrusions are corrugated, saw-toothed, pit-like, spike-like, inverted-tooth-like, or net-like structures, so as to not only increase the surface area of the transitional connection device 8, but also It is also possible to enhance the connection between the transition connection device 8 and the power transmission aluminum part 9 through the protrusions, to break more oxide layers, and to improve the conductivity.
- the inventors used the protrusions as corrugated, sawtooth, pit-shaped, spike-shaped, inverted-tooth-shaped, and net-shaped structures. Take an example to prove the influence of bumps on the performance of the power transmission joint. The results are shown in Table 3:
- the pulling force of the power transmission joint is greater than when the surface of the transition connection device 8 is not provided with protrusions
- the pulling force of the power transmission joint, and the voltage drop value is less than the voltage drop of the power transmission joint when the surface of the transition connection device 8 is not provided with bumps. Therefore, when at least part of the surface of the transition connection device 8 is provided When convex, the power transmission joint has better mechanical and electrical properties.
- the transition connection device 8 is a hollow cylinder at least partially sleeved on the aluminum guide core 4.
- the transition connection device 8 is a hollow cylinder, on the one hand, it can be realized Automatic production, high production efficiency; on the other hand, the loose aluminum guide core 4 can be pre-shrinked through the transition connection device 8, so that the aluminum guide core 4 can be inserted into the cavity more conveniently, It is avoided that part of the core wires of the aluminum guide core 4 produced during the production process cannot be inserted into the cavity, which facilitates the production and processing of the power transmission joint.
- the crimping length of the aluminum wire 3 accounts for at least 5% of the length of the power transmission aluminum part 9. The reason is that if the crimping length of the aluminum wire 3 is too short, the power transmission aluminum piece 9 has insufficient fixing force to the aluminum wire 3, which makes the aluminum wire 3 easy to separate from the power transmission aluminum piece 9; moreover, If the crimping length is too short, the contact area of the crimping place between the aluminum wire 3 and the power transmission aluminum part 9 will be reduced, and the current conduction area will be relatively small. The resistance between the aluminum transmission parts 9 increases, which causes heat at the crimping point, which reduces the electrical performance of the power transmission joint, and may cause a combustion accident in severe cases.
- Table 4 The influence of the ratio of the crimping length of the aluminum wire to the length of the power transmission aluminum part on the performance of the power transmission joint
- the crimping length of the aluminum wire 3 accounts for less than 5% of the length of the power transmission aluminum part 9, the pulling force of the power transmission joint is less than 2000N, which does not conform to the aluminum joint Mechanical performance requirements, and the voltage drop is greater than 0.5mV, which does not meet the electrical performance requirements, which seriously affects the service life of the power transmission joint. Therefore, preferably, the crimping length of the aluminum wire 3 at least accounts for the power transmission 5% of the length of the aluminum piece 9.
- the connecting piece 2 and the electric power transmission aluminum piece 9 are connected by welding.
- welding includes friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, or arc welding, among which:
- Friction welding is the use of friction welding equipment for welding, which rotates the first work piece, causes the second work piece to apply pressure to the rotating first work piece, generates heat through friction, and welds the first work piece and the second work piece together by pressure.
- its advantage is that the welding speed is fast, and there is no noise, smoke, strong light and other pollution.
- Resistance welding is a method that uses the resistance heat generated by the current passing through the weldment and the contact as a heat source to locally heat the weldment while applying pressure for welding.
- the advantages are that no filler metal is required, the productivity is high, the deformation of the weldment is small, and it is easy to realize automation.
- Ultrasonic welding uses high-frequency vibration waves to be transmitted to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects are rubbed against each other to form a fusion between the molecular layers.
- the advantage is that the welding time is short. , Without any flux, gas, solder, welding without sparks, environmental protection and safety.
- Electromagnetic welding uses an instantaneous current to generate a strong magnetic field, so that the weldments are welded together under the action of the magnetic field. Its advantages are non-contact welding, fast welding speed, low internal welding stress, and high processing accuracy.
- Pressure diffusion welding is a welding method in which two weldments are pressed together and heated and insulated, so that the weldments can diffuse between atoms to form a metallurgical connection.
- the advantage is that the weldments are overheated and do not melt, and the joints are welded. High quality, can weld large area weldment, weldment welding accuracy is high, and deformation is small.
- Arc welding uses electric arc as a heat source and uses the physical phenomenon of air discharge to convert electrical energy into thermal and mechanical energy required for welding, so as to achieve the purpose of connecting metals. Its advantage is that it does not limit the welding environment and is suitable for welding of various metal materials, various thicknesses, and various structural shapes. If precision welding is required, plasma welding can also be used. Plasma welding is a kind of arc welding, but plasma arc energy is concentrated, productivity is high, welding speed is fast, stress deformation is small, and electric isolation is more stable.
- the connecting piece 2 and the electric power transmission aluminum piece 9 are connected by friction welding. This is because the friction welding method is more effective for butt joint parts with a large cross-sectional area with through holes. For simplicity.
- copper and aluminum atoms are mutually infiltrated or combined with each other between the connecting member 2 and the power transmission aluminum member 9 to form a copper-aluminum transition layer 6, and the copper-aluminum transition layer 6 contains at least a copper element.
- a mixture of aluminum element or a mixture of copper, aluminum element and copper-aluminum solid solution, and the copper-aluminum transition layer 6 can slow down the electrochemical corrosion between copper and aluminum, and prolong the service life of the power transmission joint.
- the invention also discloses a preparation method of the electric energy transmission joint, which comprises the following steps:
- Welding step connect the connecting piece 2 of the copper power transmission part and the aluminum power transmission part 9 by welding;
- the aluminum wire 3 crimping step the exposed aluminum core 4 is stretched into the cavity after the insulating layer 5 at the front end of the aluminum wire 3 is stripped, and then the aluminum wire 3 and the power transmission aluminum piece 9 are crimped together.
- the step of filling sealant or solder 7 between the aluminum core 4 and the cavity is further included.
- filling the sealant or solder 7 into the cavity is: pour the molten sealant or solder 7 into the welded power transmission copper part and the power transmission aluminum part 9 through the hole on the surface of the power transmission copper part .
- the step of putting a transitional connection device 8 on the aluminum guide core 4 is further included.
Abstract
一种电能传输接头及其制备方法，所述电能传输接头包括电能传输铜件、电能传输铝件(9)以及铝导线(3)，所述电能传输铜件包括用于连接用电装置的固定件(1)和用于连接所述电能传输铝件(9)的连接件(2)，所述电能传输铝件(9)的内部设置有第一通孔，所述连接件(2)的内部设置第二通孔，所述铝导线(3)前端剥除绝缘层(5)后露出的铝导芯(4)伸入所述第一通孔和所述第二通孔连接而成的腔体内，并且所述电能传输铝件(9)通过压接的方式连接所述铝导线(3)。所述电能传输铜件重量轻，生产快捷，节省了生产成本。
Description
相关申请
本申请要求申请号为202010249743.8，申请日为2020年04月01日，发明名称为“一种电能传输接头及其制备方法”的中国发明专利的优先权。
本发明涉及电气连接技术领域，尤其涉及一种电能传输接头及其制备方法。
目前，在线束轻量化的大前提下，铝导线将被大量使用，但由于用电装置的接线端大多还是铜材质，因此铝导线还要和电能传输铜件连接。电能传输铜件一般都是实心的，比较浪费材料，并且，实心的电能传输铜件一般是采用热锻的方式加工的，耗费能量较高，加工误差大，电能传输铜件的制作成本较高。而且，不同形状的电能传输铜件与铝导线通过焊接的方式连接时，需要使用不同的工装夹具，增加成本、工装治具管理复杂。另外，在进行焊接时，铝导线也在焊接设备中进行焊接，由于铝导线比较长且比较软，不仅增加了设备工装成本，而且不容易实现自动化生产上下料，而在焊接结束后，由于铝导线无法旋转，从而不能对焊接产生的飞边进行清除。
因此，电气连接技术领域急需一种进一步减轻铜端子重量，减少铝线束成本的电能传输接头。
发明内容
为了克服现有技术的不足，本发明所解决的技术问题是提供一种电能传输接头，其采用带有通孔的电能传输铜件与电能传输铝件连接，进一步降低了电能传输接头的重量，明显降低了电能传输接头的制作成本。
为解决上述技术问题，本发明所采用的技术方案内容具体如下：
一种电能传输接头，包括电能传输铜件、电能传输铝件以及铝导线，所述电能传输铜件包括用于连接用电装置的固定件和用于连接所述电能传输铝件的连接件，所述电能传输铝件的内部设置有第一通孔，所述连接件的内部设置第二通孔，所述铝导线前端剥除绝缘层后露出的铝导芯伸入所述第一通孔和所述第二通孔连接而成的腔体内，并且所 述电能传输铝件通过压接的方式连接所述铝导线。
本发明还公开了一种电能传输接头的制备方法，包括如下步骤，
焊接步骤：将电能传输铜件的连接件与电能传输铝件通过焊接的方式连接在一起；
铝导线压接步骤：剥除铝导线前端的绝缘层后露出的铝导芯伸入所述腔体内，然后将铝导线和电能传输铝件压接在一起。
与现有技术相比，本发明的有益效果在于：
1、所述电能传输铜件的连接件的内部设置有第二通孔，其明显降低了所述电能传输铜件的重量，节省了生产成本，并且电能传输铜件可以使用铜管材料进行冲压成型，生产快捷简单。而且，由于所述电能传输铜件与所述电能传输铝件的体积相对较小，可以实现电能传输铜件与电能传输铝件上下料的自动化，而且还可以在焊接后直接切除连接件和电能传输铝件焊接时产生的飞边，节省了加工时间，大大提高了装配的效率。
2、由于所述连接件的内部设置的第二通孔、以及所述电能传输铝件的内部设置的第一通孔连接而成的腔体内填充有密封胶或焊料，一方面，所述密封胶或所述焊料排出了所述腔体内的空气，避免空气和水对所述连接件和所述电能传输铝件的腐蚀；另一方面，由于所述电能传输铝件的材质较软，其压接铝导线时可能会导致所述电能传输接头的力学性能不足，而所述焊料可以使得所述连接件、所述电能传输铝件以及所述铝导芯连接在一起，加强了所述电能传输接头对所述铝导线的连接强度。另外，所述焊料增加了所述铝导芯与所述连接件、以及所述电能传输铝件的接触面积，进一步提高了所述电能传输接头的电学性能。
3、所述铝导芯与所述腔体内壁之间还设置有过渡连接装置，并且所述过渡连接装置的至少部分表面设置有凸起，所述凸起用于刺破所述铝导芯表面和所述腔体表面的氧化层，从而通过所述凸起减少了所述铝导线与所述电能传输铝件之间的电阻，提高了所述铝导线与所述电能传输铝件压接区域的导电性能，降低了该压接区域因为电阻增大所引发的发热导致的燃烧事故。
4、所述铝导线的压接长度至少占所述电能传输铝件长度的5％，进一步增加了所述电能传输铝件的连接强度，增加所述电能传输铝件的导电性能。
5、所述电能传输铝件的内径为所述铝导线绝缘层外接圆直径的1倍～3倍。既避免所述铝导线无法插入所述电能传输铝件，也可以确保使电能传输铝件与所述铝导线在压接时不会因为变形量过大而导致破裂。
6、所述过渡连接装置为至少部分套接在所述铝导芯上的空心柱体，一方面，所述 过渡连接装置安装的大批量自动化生产，提高生产效率；另一方面，所述过渡连接装置可以将松散的铝导芯进行预收缩，使所述铝导芯能够更加方便的插入到所述腔体中，避免生产过程中产生的铝导芯的部分芯线在所述腔体之外的情况，提高所述电能传输接头的产品质量。
7、所述连接件与所述电能传输铝件之间形成以铜铝原子互相渗透或相互结合的铜铝过渡层，所述铜铝过渡层能够有效的减少铜铝之间的电化学腐蚀，延长电能传输接头的使用寿命约20％；而且，所述连接件和所述电能传输铝件通过摩擦焊接的方式连接，其可以提高生产效率约26％，减少人工数量，避免人员疲劳导致的误操作，降低安全事故，提高产品质量。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，而可依照说明书的内容予以实施，并且为了让本发明的上述和其他目的、特征和优点能够更明显易懂，以下特举较佳实施例，并配合附图，详细说明如下。
图1为本发明所述的电能传输接头的结构示意图；
其中，图1的附图标记为：
1、固定件；2、连接件；3、铝导线；4、铝导芯；5、绝缘层；6、铜铝过渡层；7、密封胶或焊料；8、过渡连接装置；9、电能传输铝件。
为更进一步阐述本发明为达成预定发明目的所采取的技术手段及功效，以下结合附图及较佳实施例，对依据本发明的具体实施方式、结构、特征及其功效，详细说明如下：
如图1，本发明公开了一种电能传输接头，其包括电能传输铜件、电能传输铝件9以及铝导线3，所述电能传输铜件包括用于连接用电装置的固定件1和用于连接所述电能传输铝件9的连接件2，所述连接件2的内部设置第二通孔，所述电能传输铝件9的内部设置有第一通孔，所述铝导线3前端剥除绝缘层5后伸入所述第一通孔和所述第二通孔连接而成的腔体内，并且所述电能传输铝件9通过压接的方式连接所述铝导线3。
由于所述连接件2的内部设置有第二通孔，大大降低了所述电能传输铜件的重量，节省了生产成本；而且，所述电能传输接头连接时，首先所述电能传输铜件的连接件2与所述电能传输铝件9连接，然后将铝导线3前端剥除绝缘层5后伸入第一通孔和第二 通孔连接而成的腔体内，最后将电能传输铝件9和所述铝导线3压接而成，其连接方式简单，可实现所述电能传输接头装配的自动化，大大提高了装配效率。
而且，由于所述电能传输铜件与所述电能传输铝件9的体积相对较小，可以实现电能传输铜件与电能传输铝件9上下料的自动化；而且，还可以在焊接后直接切除连接件2和电能传输铝件9焊接时产生的飞边，使得所述电能传输接头在切除飞边时不带所述铝导线3，不仅节省了加工时间，提高了装配的效率，而且还可以避免带所述铝导线3进行飞边切除时对所述电能传输接头产生的影响，提高了所述电能传输接头的成品率。
需要说明的是，在本发明中，所述电能传输铜件是由管状的铜管冲压成型而成，并且冲压成型的电能传输铜件包括固定件1和连接件2，且连接件2的内部设置有第二通孔；而且，所述铝导线3前端的伸入所述腔体内的位置可以位于所述第一通孔内，也可以位于所述第二通孔内。
由于铜属于活泼金属，电能传输铜件在使用的过程中容易受到氧化腐蚀，从而增加所述电能传输铜件的电阻，严重时可能引发燃烧事故，因此，为了延长所述电能传输铜件的使用寿命，所述固定件1和所述连接件2的表面设置有镀层，并且所述镀层的材质至少含有镍、镉、锆、铬、钴、锰、铝、锡、钛、锌、铜、银或金中的一种，从而通过所述镀层降低所述电能传输铜件的氧化腐蚀速度，延长电能传输铜件的使用寿命。
作为一种优选的方案，所述电能传输铝件9的内径为所述铝导线绝缘层5外接圆直径的1倍～3倍。一方面，其可以便于所述铝导线3前端剥除绝缘层5后伸入所述第一通孔和所述第二通孔连接而成的腔体内；另一方面，由于所述电能传输铝件9通过压接的方式连接所述铝导线3，因此，如果所述电能传输铝件9的内径大于所述铝导线绝缘层5外接圆直径的3倍以上，则所述电能传输铝件9需要压缩较大的比例才可以确保压接到所述铝导线3上，容易导致所述电能传输铝件9出现破裂。
为了验证电能传输铝件的内径与所述铝导线绝缘层5外接圆直径的比值对所述电能传输接头的拉拔力和电压降的影响，考察了不同电能传输铝件9的内径与所述铝导线绝缘层5外接圆直径的比值制作的电能传输接头的拉拔力和电压降，实验结果如表1所示：
表1：电能传输铝件的内径与所述铝导线绝缘层外接圆直径的比值对电能传输接头性能的影响
根据表1的可知，当电能传输铝件9的内径与所述铝导线绝缘层5外接圆直径的比值小于1时，所述铝导线3无法插入到电能传输铝件的内部；当电能传输铝件9的内径与所述铝导线绝缘层5外接圆直径的比值大于3时，电能传输接头的拉拔力低于2000N的标准值，电能传输接头的电压降高于0.5mV的标准值，已不符合电能传输接头的力学性能和电学性能的要求；而且，当电能传输铝件9的内径与所述铝导线绝缘层5外接圆直径的比值较大时，则所述电能传输铝件9需要压缩较大的比例才可以确保压接到所述铝导线3上，容易导致所述电能传输铝件9出现破裂。
所述铝导线3前端剥除绝缘层5后露出的铝导芯4与所述腔体之间填充有密封胶或焊料7，一方面，所述密封胶或焊料7排出了所述腔体内的空气，避免腔体中的空气和水对所述连接件2和所述电能传输铝件9的腐蚀；另一方面，由于所述电能传输铝件9的材质较软，其压接铝导线3时可能会导致所述电能传输接头的力学性能不足，而所述密封胶或焊料7使得所述连接件2、所述电能传输铝件9以及所述铝导芯4连接在一起，加强了所述电能传输接头的对所述铝导线3的连接强度。另外，所述焊料7增加了所述铝导芯4与所述连接件2、以及所述电能传输铝件9的接触面积，进一步提高了所述电能传输接头的电学性能。
需要说明的是，在本发明中，所述焊料的材质至少含有镍及镍合金、镉及镉合金、锆及锆合金、铬及铬合金、钴及钴合金、锰及锰合金、锡及锡合金、钛及钛合金、锌及锌合金、铜及铜合金、银及银合金或金及金合金中的一种。作为一种优选的方式，所述焊料的材质为熔点不高于铝的金属或合金。
而且，由于所述密封胶7具有良好的延展性和密封性，当所述铝导芯4与所述腔体之间填充有密封胶7时，所述密封胶7能够将所述铝导芯4与所述腔体之间的区域进行密封保护，使得所述铝导芯4与所述腔体极大地减少受潮湿、盐雾的侵蚀，从而延长了所述电能传输接头的使用寿命。
密封胶7包含但不限于导电胶、橡胶类密封胶、树脂类密封胶或油类密封胶。
为了了解密封胶或焊料对所述电能传输接头性能的影响，发明人进行了实验二，且实验结果如表2所示：
表2 密封胶或焊料对所述电能传输接头性能的影响
从上表可以看出：当所述铝导芯4与所述腔体之间填充密封胶或焊料时，所述电能传输接头的拉拔力值明显大于所述铝导芯4与所述腔体之间没有填充密封胶或焊料时的电能传输接头，而电压降值则小于所述铝导芯4与所述腔体之间没有填充密封胶或焊料时的电能传输接头，因此，当所述铝导芯4与所述腔体之间填充密封胶或焊料时，所述电能传输接头具有更好的电学性能和力学性能。
作为进一步优选的方案，所述铝导芯4与所述腔体内壁之间还设置有过渡连接装置8，并且所述过渡连接装置8的至少部分表面设置有凸起，所述凸起用于刺破所述铝导芯4表面和所述腔体内壁表面的氧化层。
需要说明的是，在本发明中，所述过渡连接装置8的材质至少含有镍及镍合金、镉及镉合金、锆及锆合金、铬及铬合金、钴及钴合金、锰及锰合金、锡及锡合金、钛及钛合金、锌及锌合金、铜及铜合金、银及银合金或金及金合金中的一种。
一方面，所述凸起增加了所述铝导芯4、所述过渡连接装置8以及所述电能传输铝件9之间的接触面积，增加了所述铝导线3和所述过渡连接装置8、以及所述过渡连接装置8与所述电能传输铝件9之间的摩擦力，从而能够防止铝导线3脱离所述电能传输铝件9，使得所述电能传输接头具有更好的力学性能。
另一方面，所述凸起还增加了所述铝导芯4的导电凸点，增强了导电效果，同时也会破坏所述铝导芯4表面和所述腔体内壁表面的氧化层，使得铝导芯4与所述过渡连接装置8、以及所述过渡连接装置8与所述腔体的导电部分直接接触，提高所述电能传输接头的电学性能。
具体设置时，所述凸起为波纹状结构或锯齿状结构或凹坑状结构或尖刺状结构或倒牙状结构或网状结构，从而不仅可以增加所述过渡连接装置8的表面积，而且也可以通过所述凸起增强所述过渡连接装置8与电能传输铝件9之间连接，破除更多的氧化层，提高导电率。
为了了解所述凸起对所述电能传输接头性能的影响，发明人以所述凸起为波纹状结构、锯齿状结构、凹坑状结构、尖刺状结构、倒牙状结构以及网状结构为例证明凸起对所述电能传输接头性能的影响，结果如表3所示：
表3 凸起对所述电能传输接头性能的影响
从上表可以看出，当所述过渡连接装置8的至少部分表面设置以上形状结构的凸起时，所述电能传输接头的拉拔力大于所述过渡连接装置8的表面不设置凸起时的电能传输接头的拉拔力，而电压降值则小于所述过渡连接装置8的表面不设置凸起时的电能传输接头的电压降，因此，当所述过渡连接装置8的至少部分表面设置凸起时，所述电能传输接头具有更好的力学性能和电学性能。
在其他的实施例中，所述过渡连接装置8为至少部分套接在所述铝导芯4上的空心柱体，当所述过渡连接装置8为空心柱体时，一方面，其可以实现自动化生产，生产效率高；另一方面，通过所述过渡连接装置8可以将松散的铝导芯4进行预收缩，使所述铝导芯4能够更加方便的插入到所述腔体中，以避免生产过程中产生的铝导芯4的部分芯线不能插入所述腔体的内部，方便了所述电能传输接头的生产和加工。
为了确保所述电能传输铝件9与所述铝导线3压接后具有更好的压接效果，所述铝导线3的压接长度至少占所述电能传输铝件9长度的5％，这是因为如果所述铝导线3的压接长度过短，所述电能传输铝件9对铝导线3的固定力不足，进而使得所述铝导线3容易脱离所述电能传输铝件9；而且，如果压接长度过短，也会使得所述铝导线3与所述电能传输铝件9的压接处的接触面积变小，电流导通区域相对较小，所述铝导线3 与所述电能传输铝件9之间的电阻增大，使得压接处发热，降低了所述电能传输接头的电学性能，严重时可能引发燃烧事故。
为了了解所述铝导线3的压接长度占所述电能传输铝件9长度的比例对所述电能传输接头性能的影响，发明人考察了不同铝导线3的压接长度占所述电能传输铝件9长度的比例，然后对上述的电能传输接头的力学性能和电学性能进行测试，具体测试结果如表4所示：
表4 铝导线的压接长度占所述电能传输铝件长度的比例对所述电能传输接头性能的影响
从上表中可以看出，当所述铝导线3的压接长度占所述电能传输铝件9长度的比例小于5％时，所述电能传输接头的拉拔力小于2000N，不符合铝接头力学性能的要求，且电压降大于0.5mV，不符合电学性能要求，严重影响了所述电能传输接头的使用寿命，因此，优选地，所述铝导线3的压接长度至少占所述电能传输铝件9长度的5％。
作为进一步优选的方案，所述连接件2和所述电能传输铝件9通过焊接的方式连接。
需要说明的是：焊接包括摩擦焊接或电阻焊接或超声波焊接或电磁焊接或压力扩散焊接或弧焊接等方式，其中：
(1)摩擦焊接是利用摩擦焊设备进行焊接，其使第一工件旋转，使第二工件向旋转的第一工件施加压力，通过摩擦生热，依靠压力将第一工件和第二工件焊接在一起，其优点是焊接速度快，且无噪声、烟雾、强光等污染。
(2)电阻焊接是利用电流通过焊件及接触处产生的电阻热作为热源将焊件局部加热，同时加压进行焊接的方法。其优点是不需要填充金属，生产率高，焊件变形小，容易实现自动化。
(3)超声波焊接是利用高频振动波传递到两个需焊接的物体表面，在加压的情况下，使两个物体表面相互摩擦而形成分子层之间的熔合，其优点是焊接时间短，不需任 何助焊剂、气体、焊料，焊接无火花，环保安全。
(4)电磁焊接是利用瞬间的电流产生强磁场，使焊件在磁场力的作用下，焊接在一起，其优点是属于非接触焊接，焊接速度快，焊接内部应力小，加工精度高。
(5)压力扩散焊接是将两个焊件紧压在一起，通过加热保温，使焊件达到原子间相互扩散而成冶金连接的焊接方法，其优点是焊件不过热、不熔化，焊接接头质量高，可以焊接大面积焊件，焊件焊接精度高，变形小。
(6)弧焊接是使用电弧作为热源，利用空气放电的物理现象，将电能转换为焊接所需的热能和机械能，从而达到连接金属的目的。其优点是不限制焊接环境，适用于各种金属材料、各种厚度、各种结构形状的焊接。如果需要精密焊接，也可以使用等离子焊接，等离子焊接属于弧焊的一种，但是等离子电弧能量集中、生产率高、焊接速度快、应力变形小、电孤更加稳定。
作为进一步优选的方式，所述连接件2和所述电能传输铝件9通过摩擦焊接的方式连接，这是由于对于具有带有通孔的大截面积的对接零件而言，摩擦焊接的方式更为简单。
作为进一步优选的方案，所述连接件2与所述电能传输铝件9之间以铜铝原子互相渗透或相互结合形成铜铝过渡层6，并且所述铜铝过渡层6至少包含了铜单质、铝单质的混合物或者铜、铝单质与铜铝固溶体的混合物，而且，通过所述铜铝过渡层6可以减缓铜铝之间的电化学腐蚀，延长所述电能传输接头的使用寿命。
本发明还公开了一种电能传输接头的制备方法，包括如下步骤，
焊接步骤：将电能传输铜件的连接件2与电能传输铝件9通过焊接的方式连接在一起；
铝导线3压接步骤：剥除铝导线3前端的绝缘层5后露出的铝导芯4伸入腔体内，然后将铝导线3和电能传输铝件9压接在一起。
进一步地，在焊接步骤与铝导线3压接步骤之间，还包括向所述铝导芯4与所述腔体之间填充密封胶或焊料7的步骤。
具体地，向腔体内填充密封胶或焊料7为：通过所述电能传输铜件表面的孔洞，向焊接完成的电能传输铜件和电能传输铝件9内部，灌入熔融的密封胶或焊料7。
进一步优选地，在向腔体内填充密封胶或焊料7的步骤与铝导线3压接步骤之间，还包括向铝导芯4上套过渡连接装置8的步骤。
需要说明的是，在本发明的描述中，术语“第一”、“第二”等仅用于描述各部件 的名称，而不能理解为指示或暗示各部件的相对重要性。
上述实施方式仅为本发明的优选实施方式，不能以此来限定本发明保护的范围，本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要求保护的范围。
Claims (13)
- 一种电能传输接头，包括电能传输铜件、电能传输铝件以及铝导线，所述电能传输铜件包括用于连接用电装置的固定件和用于连接所述电能传输铝件的连接件，其中：所述电能传输铝件的内部设置有第一通孔，所述连接件的内部设置第二通孔，所述铝导线前端剥除绝缘层后露出的铝导芯伸入所述第一通孔和所述第二通孔连接而成的腔体内，并且所述电能传输铝件通过压接的方式连接所述铝导线。
- 如权利要求1所述的电能传输接头，其中：所述电能传输铝件的内径为所述铝导线绝缘层外接圆直径的1倍～3倍。
- 如权利要求1所述的电能传输接头，其中：所述铝导芯与所述腔体之间填充有密封胶或焊料。
- 如权利要求1所述的电能传输接头，其中：所述铝导芯与所述腔体内壁之间还设置有过渡连接装置，并且所述过渡连接装置的至少部分表面设置有凸起，所述凸起用于刺破所述铝导芯表面和所述腔体内壁表面的氧化层。
- 如权利要求4所述的电能传输接头，其中：所述凸起为波纹状结构或锯齿状结构或凹坑状结构或尖刺状结构或倒牙状结构或网状结构。
- 如权利要求4所述的电能传输接头，其中：所述过渡连接装置为至少部分套接在所述铝导芯上的空心柱体。
- 如权利要求1所述的电能传输接头，其中：所述铝导线的压接长度至少占所述电能传输铝件长度的5％。
- 如权利要求1所述的电能传输接头，其中：所述连接件和所述电能传输铝件通过焊接的方式连接。
- 如权利要求8所述的电能传输接头，其中：所述连接件和所述电能传输铝件通过摩擦焊接的方式连接。
- 如权利要求8所述的电能传输接头，其中：所述连接件与所述电能传输铝件之间形成以铜铝原子互相渗透或相互结合的铜铝过渡层。
- 一种如权利要求1至10中任何一项所述的电能传输接头的制备方法，其中：包括如下步骤，焊接步骤：将电能传输铜件的连接件与电能传输铝件通过焊接的方式连接在一起；铝导线压接步骤：剥除铝导线前端的绝缘层后露出的铝导芯伸入所述腔体内，然后将铝导线和电能传输铝件压接在一起。
- 如权利要求11所述的制备方法，其中：还包括向所述铝导芯与所述腔体之间填充密封胶或焊料的步骤。
- 如权利要求11所述的制备方法，其中：还包括在铝导芯上设置过渡连接装置的步骤。
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| CN107302143A (zh) * | 2017-05-23 | 2017-10-27 | 广东林新能源科技有限公司 | 连接线、电连接器端子及制造方法 |
| CN111326873A (zh) * | 2020-04-01 | 2020-06-23 | 吉林省中赢高科技有限公司 | 一种电能传输接头及其制备方法 |
| CN211507944U (zh) * | 2020-04-01 | 2020-09-15 | 吉林省中赢高科技有限公司 | 一种电能传输接头 |
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| JPS4830300Y1 (zh) * | 1969-03-13 | 1973-09-14 | ||
| JPS5130627Y1 (zh) * | 1970-05-09 | 1976-08-02 | ||
| JPS5933172Y2 (ja) * | 1981-03-12 | 1984-09-17 | 矢崎総業株式会社 | 端子金具 |
| JP2003338350A (ja) | 2002-05-20 | 2003-11-28 | Mitsubishi Cable Ind Ltd | 端子接続方法及び端子接続構造 |
| CN106450868B (zh) * | 2016-11-04 | 2019-03-26 | 吉林省中赢高科技有限公司 | 一种铝端子和铜铝过渡连接器 |
| CN107123866B (zh) * | 2017-06-05 | 2019-03-26 | 吉林省中赢高科技有限公司 | 一种铜端子和铝导线的接头及其等离子焊接方法 |
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- 2020-04-01 CN CN202010249743.8A patent/CN111326873A/zh active Pending
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2021
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| US20060160408A1 (en) * | 2005-01-18 | 2006-07-20 | Thierry Quillet | Intermediate element for establishing a connection between a cable and a contact element, and connector assembly |
| CN105305124A (zh) * | 2015-10-29 | 2016-02-03 | 广州番禺电缆集团有限公司 | 一种电线转接装置单体及由其构成的一体式电线转接装置 |
| CN107302143A (zh) * | 2017-05-23 | 2017-10-27 | 广东林新能源科技有限公司 | 连接线、电连接器端子及制造方法 |
| CN111326873A (zh) * | 2020-04-01 | 2020-06-23 | 吉林省中赢高科技有限公司 | 一种电能传输接头及其制备方法 |
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Also Published As
| Publication number | Publication date |
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| JP7348413B2 (ja) | 2023-09-20 |
| JP2023512332A (ja) | 2023-03-24 |
| EP4131665A4 (en) | 2023-10-11 |
| MX2022012400A (es) | 2023-01-18 |
| ZA202210952B (en) | 2023-05-31 |
| CN111326873A (zh) | 2020-06-23 |
| US20230231328A1 (en) | 2023-07-20 |
| CA3173365A1 (en) | 2021-10-07 |
| EP4131665A1 (en) | 2023-02-08 |
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