WO2024056048A1 - 一种新型铝端子 - Google Patents

一种新型铝端子 Download PDF

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Publication number
WO2024056048A1
WO2024056048A1 PCT/CN2023/118982 CN2023118982W WO2024056048A1 WO 2024056048 A1 WO2024056048 A1 WO 2024056048A1 CN 2023118982 W CN2023118982 W CN 2023118982W WO 2024056048 A1 WO2024056048 A1 WO 2024056048A1
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WO
WIPO (PCT)
Prior art keywords
aluminum
insert
terminal according
hole
aluminum terminal
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Application number
PCT/CN2023/118982
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English (en)
French (fr)
Inventor
王超
Original Assignee
长春捷翼汽车科技股份有限公司
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Publication of WO2024056048A1 publication Critical patent/WO2024056048A1/zh

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Classifications

    • 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
    • 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

Definitions

  • the present application relates to the field of electrical connections, and more specifically, to a new type of aluminum terminal.
  • the electrical connection field urgently needs a new aluminum terminal that can slow down the electrochemical corrosion between copper and aluminum and extend the service life of the electrical connection structure.
  • the aluminum terminal is used to electrically connect aluminum cables and electrical devices and to conduct current.
  • the aluminum terminal includes a connecting portion and a Functional part, the connecting part is connected to the conductive part of the aluminum cable, and the functional part is connected to the electrical device; at least the functional part is made of aluminum, and at least one throughput is provided on the functional part.
  • hole, an insert is provided in the through hole, and the through hole and the insert are at least partially connected through a transition connection layer.
  • the transition connection layer is a plating layer provided on the insert.
  • the composition of the transition connection layer contains iron, carbon, nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium-nickel One or more of alloy, graphite silver, graphene silver and silver gold zirconium alloy.
  • the transition connection layer contains no less than 6 wt% aluminum-based solid solution.
  • the transition connection layer contains no more than 46.6 wt% aluminum-based compound.
  • the insert is made of metal, and the transition connection layer is formed by welding on at least part of the connection surface between the insert and the functional part.
  • the welding method is laser welding, friction stir welding, pressure welding, ultrasonic welding or electromagnetic welding.
  • the insert protrudes from the surface of the functional part.
  • mounting holes are provided on the insert.
  • the mounting hole is axially coincident or parallel to the through hole.
  • the through hole is a stepped hole, and a stepped platform is provided on the outer periphery of the insert, and the stepped platform is matched with the stepped hole.
  • a stepped platform is provided on the outer periphery of the insert, and a smaller side of the stepped platform is matched and installed with the through hole.
  • stepped platforms are provided on the periphery of the two inserts.
  • the smaller side of the stepped platform is matched and installed with the through hole from both sides of the through hole. .
  • mounting studs are provided on the insert.
  • the mounting stud is axially coincident or parallel to the through hole.
  • the insert is integrally formed with the mounting stud.
  • the insert has a radial dimension greater than the diameter of the mounting stud.
  • the cross-sectional shape of the transition connection layer is a triangle, a quadrilateral, a cone, a parabola or a half-wedge.
  • the width of the cross-section of the transition connection layer in the direction from the insert to the functional part is 0.01mm-5mm at the widest position.
  • the connecting part and the functional part are integrally formed.
  • the connecting part is a flat structure or a cylindrical structure, a U-shaped opening structure or a V-shaped opening structure.
  • the connecting portion and the conductive part of the aluminum cable are connected by crimping, welding, bonding or riveting.
  • the conductive part of the aluminum cable is a solid aluminum conductor, and the connecting part is integrally formed with the solid aluminum conductor.
  • the new aluminum terminals of the present application are used to replace the currently common copper materials to make terminals.
  • the cost of the terminals can be reduced, the weight of the terminals can be reduced, and the copper terminals and aluminum wires can be effectively solved. Eliminates the problem of electrochemical corrosion in direct contact and improves the service life of terminal blocks.
  • a metal insert is added, and the insert is connected to the electrical device. This not only solves the problem that the aluminum base material is soft and easy to deform, but also slows down the connection between the aluminum base material and the electrical device. electrochemical corrosion between them, extending the service life of aluminum terminals.
  • a transition connection layer is set between the insert and the aluminum base material.
  • the transition connection layer material is selected with a potential between the copper potential and the aluminum potential, which can effectively slow down the electrochemical corrosion between copper and aluminum. In the field of electrical connections, it can It effectively solves the problem of electrochemical corrosion caused by direct contact between inserts and aluminum substrates, and improves the service life of aluminum terminals.
  • Figure 1 is a cross-sectional view of an aluminum terminal according to the first embodiment of the present application.
  • Figure 2 is a cross-sectional view of an aluminum terminal according to the second embodiment of the present application.
  • Figure 3 is a cross-sectional view of an aluminum terminal according to the third embodiment of the present application.
  • Figure 4 is a cross-sectional view of an aluminum terminal according to the fourth embodiment of the present application.
  • connection part 2. Function part; 21. Insert; 22. Transition connection layer; 3. Through hole; 41. Wire core; 42. Insulating layer.
  • any specific values are to be construed as illustrative only and not as limiting. Accordingly, other examples of the exemplary embodiments may have different values.
  • the aluminum terminal is used to electrically connect aluminum cables and electrical devices and conduct current.
  • the aluminum terminal includes a connecting part 1 and a functional part 2.
  • the connecting part 1 and the aluminum wire The conductive part of the cable is connected, and the functional part 2 is connected to the electrical device.
  • the material of the functional part 2 is aluminum or aluminum alloy.
  • At least one through hole 3 is provided on the functional part 2.
  • An insert 21 is provided in the through hole 3.
  • the through hole 3 is connected to the electrical device.
  • the inserts 21 are connected to each other at least partially through a transition connection layer 22 .
  • the new aluminum terminal according to the present application includes a connecting part 1 and a functional part 2 made of aluminum or aluminum alloy.
  • the connecting part 1 is connected to the conductive part of the aluminum cable, and the functional part is 2 is connected to the electrical device, and in the functional part 2 At least one through hole 3 is provided on the through hole 3, and an insert 21 is provided in the through hole 3.
  • the through hole 3 and the insert 21 are at least partially connected through a transition connection layer 22.
  • the new aluminum terminals of this application are used to replace the currently common copper materials to make terminals. In the field of electrical connections, the cost of the terminals can be reduced, the weight of the terminals can be reduced, and the problem of electrochemical corrosion caused by direct contact between copper terminals and aluminum wires can be effectively solved. , improve the service life of the terminal block.
  • a metal insert is added, and the insert 21 is connected to the electrical device, which can not only solve the problem that the aluminum base material is soft and easy to deform, but also slow down the connection between the aluminum base material and electricity consumption. Electrochemical corrosion between devices, extending the life of aluminum terminals.
  • a transition connection layer 22 is provided between the insert 21 and the aluminum base material.
  • the transition connection layer 22 is made of a material with a potential between the copper potential and the aluminum potential, which can effectively slow down the electrochemical corrosion between copper and aluminum. In the electrical connection field, can effectively solve the problem of electrochemical corrosion caused by direct contact between the insert 21 and the aluminum base material, and improve the service life of the aluminum terminal.
  • the transition layer 22 is a plating layer disposed on the insert 21 .
  • the transition connection layer 22 is provided as a plating layer on the insert 21 to improve the corrosion resistance of the aluminum terminal.
  • the transition connection layer 22 is made of a material with a potential between the copper potential and the aluminum potential, which can effectively slow down the electrical potential between copper and aluminum. Chemical corrosion, in the field of electrical connection, can effectively solve the problem of electrochemical corrosion caused by direct contact between the insert 21 and the aluminum base material, and improve the service life of the aluminum terminal.
  • the composition of the transition connection layer 22 is iron, carbon, nickel, cadmium, manganese, zirconium, cobalt, tin, titanium, chromium, gold, silver, zinc, tin-lead alloy, silver-antimony alloy, palladium, palladium One of nickel alloy, graphite silver, graphene silver and silver gold zirconium alloy.
  • spray salt spray take it out and clean it every 20 hours to observe the surface corrosion, that is, 20 hours is a cycle.
  • the surface corrosion area of the aluminum terminal sample exceeds 10% of the total area, stop the test and record the number of cycles at that time. In this embodiment, if the number of cycles is less than 80, it is considered unqualified.
  • the transition connection layer 22 is made of gold, silver, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy
  • the experimental results exceed the standard value. More, the performance is relatively stable.
  • the material of the connection layer 22 is nickel, tin, tin-lead alloy, and zinc
  • the experimental results can also meet the requirements. Therefore, the inventor chooses the material of the transition connection layer 22 to contain iron, carbon, gold, silver, nickel, tin, and tin-lead alloy. , zinc, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy.
  • the transition tie layer 22 contains no less than 6 wt% aluminum-based solid solution. Adding alloying elements to pure aluminum forms an aluminum-based solid solution, which causes lattice distortion, hinders dislocation movement, strengthens the solid solution, and improves the strength of the aluminum-based solid solution. According to the general rules of alloying, when an infinite solid solution or high When the concentration of solid solution alloy is high, it not only has high strength, but also has good plasticity and good pressure processing properties. Binary alloys such as aluminum-copper, aluminum-magnesium, aluminum-silicon, aluminum-zinc, and aluminum-manganese can generally form limited solid solutions, have high ultimate solubility, and have good solid solution strengthening effects.
  • the higher potential difference between the materials of the insert 21 and the functional part 2 will be separated by the aluminum-based solid solution.
  • the transition connection layer 22 contains no less than 6 wt% aluminum-based solid solution.
  • transition tie layer 22 contains no greater than 46.6 wt % of the aluminum-based compound. If the amount of alloying elements added to aluminum exceeds the limit solubility, when heated for solution treatment, a part of the second phase that cannot be dissolved in the solid solution appears, which is called an excess phase. In aluminum alloys, these excesses are usually hard and brittle intermetallic compounds. They hinder dislocation movement in the alloy and strengthen the alloy, which is called overphase strengthening. At this time, the brittleness of the transition connection layer 22 increases, which is not conducive to the mechanical properties between the insert 21 and the functional part 2 .
  • the material of the insert 21 is metal
  • the transition connection layer 22 is formed by welding on at least part of the connection surface between the insert 21 and the functional part 2 .
  • the material of the insert 21 can be selected from one of iron, copper, gold, silver, nickel, tin, tin-lead alloy, zinc, silver-antimony alloy, palladium, palladium-nickel alloy, graphite silver, graphene silver and silver-gold-zirconium alloy. Or its alloy, it can increase the conductivity of aluminum terminals and enhance the hardness of aluminum terminals to achieve better electrical and mechanical properties when connected to electrical devices.
  • the transition connection layer 22 will be formed by welding at least part of the connection surface between the insert 21 and the functional part 2 .
  • the welding method is laser welding, friction stir welding, pressure welding, ultrasonic welding or electromagnetic welding.
  • Laser welding is an efficient and precise welding method that uses high-energy-density laser beams as heat sources.
  • Friction stir welding refers to the use of heat generated by the friction between the high-speed rotating welding tool and the workpiece to locally melt the material to be welded.
  • the plasticized material is plasticized under the action of the rotational friction of the welding tool. It flows from the front to the rear of the welding tool, and forms a dense solid phase weld under the extrusion of the welding tool.
  • Pressure welding is a method of applying pressure to the weldment to bring the joint surfaces into close contact and produce a certain degree of plastic deformation to complete the welding.
  • Ultrasonic welding uses high-frequency vibration waves to transmit to the surfaces of two objects to be welded. Under pressure, the surfaces of the two objects rub against each other to form fusion between the molecular layers.
  • the insert 21 protrudes from the surface of the functional part 2 . As shown in Figures 2 to 4, the insert 21 protrudes from the surface of the functional part 2, which can ensure that the bolts do not come into contact with the surface of the functional part 2 when bolts are used to fix the functional part 2, and prevent electrochemical reactions between the bolts and the surface of the functional part 2. .
  • mounting holes are provided on the insert 21 .
  • an insert 21 is provided in the through hole 3.
  • the insert 21 and the functional part 2 are fixed together. Therefore, it is necessary to provide a mounting hole on the insert 21 to ensure that the bolts can be used. fixed.
  • the mounting hole is axially coincident or parallel to the through hole 3 .
  • bolts are used to connect the functional part 2 to the electrical device through the through hole 3, and the mounting hole on the insert 21 needs to be axially coincident or parallel to the through hole 3.
  • the through hole 3 is a stepped hole
  • the insert 21 is provided with a stepped platform on its outer periphery, and the stepped platform is matched with the stepped hole.
  • a stepped platform is provided on the outer periphery of the insert 21, as shown in Figures 2 and 3, and the corresponding through hole 3 is set as a stepped hole to ensure that the insert
  • the cross-sectional area of the end of 21 is larger than the cross-sectional area of other parts, which can ensure that the surface of the end and the functional part 2 are flush, so that the functional part 2 does not come into contact with the bolt, and the material of the insert 21 can be saved.
  • the smaller side of the stepped platforms are matched and installed with the through hole 3 from both sides of the through hole 3 .
  • the two upper and lower inserts 21 are arranged opposite each other in the through hole 3.
  • the smaller side of the step platform is matched with the through hole 3 from both sides of the through hole 3.
  • insert 21 is provided with mounting studs. In some embodiments, mounting studs are provided on the insert 21 to facilitate direct connection of the copper and aluminum terminals to electrical devices.
  • the mounting studs are axially coincident or parallel to the through hole 3 .
  • insert 21 is integrally formed with the mounting stud.
  • the mounting stud and the insert 21 are integrally formed to facilitate processing. It also ensures that the mounting stud is not easily lost during the installation of the copper-aluminum terminal, and is directly connected to the electrical device to simplify the installation steps.
  • the radial dimension of insert 21 is larger than the diameter of the mounting stud. Since the mounting stud needs to extend into the insert 21 to connect the insert 21 and the functional part 2 to the electrical device, the radial dimension of the insert 21 is larger than the diameter of the mounting stud.
  • the cross-sectional shape of the transition layer 22 is a triangle, a quadrilateral, a cone, a parabola, or a half-wedge. As shown in FIGS. 1 to 4 , the cross section of the transition connection layer 22 is triangular.
  • the transition connection layer 22 can form cross-sections of different shapes, that is, welds, through different welding methods. Properly setting the shape of the welds can increase the connection strength and conductive performance of the connection part 1 and the functional part 2.
  • the width of the cross section of the transition connection layer 22 along the direction from the connection part 1 to the functional part 2 of the insert 21 is 0.01 mm-5 mm at the widest position.
  • the width of the widest position of the transition connection layer 22 cannot be less than 0.01mm.
  • An excessively narrow transition connection layer 22 may cause a gap between the connection part 1 and the functional part 2.
  • the connection strength is not high, causing the insert 21 to separate from the functional part 2 during use; at the same time, the inventor has verified through repeated tests that an excessively large transition connection layer 22 will not increase the gap between the connection part 1 and the functional part 2.
  • the transition connection In order to form an excessively large transition connection layer 22, greater welding energy is required, which will produce more copper-aluminum compounds in the transition connection layer 22, thereby affecting the conductive performance of the aluminum terminal. Therefore, the transition connection The width of layer 22 at its widest point shall not be greater than 5 mm.
  • the connecting part 1 and the functional part 2 are integrally formed.
  • the connecting part 1 and the functional part 2 are integrally formed, which can save processing steps and improve the strength of the terminal.
  • the connecting part 1 is a flat structure or a cylindrical structure or a U-shaped opening structure or a V-shaped opening structure. As shown in Figure 1 and Figure 4, the connecting part 1 is a U-shaped opening structure and a cylindrical structure respectively.
  • the connecting part 1 is designed into different shapes so that the aluminum terminals can be connected to aluminum cables in different connection methods according to actual needs. , it also optimizes the process structure of electrical products, reduces processing time, and reduces production and operation costs.
  • the connecting part 1 When the connecting part 1 has a flat structure, it generally uses welding or conductive glue to connect the aluminum cables. Since the connection area between the connecting part 1 and the aluminum cable is small, it is suitable for situations where the installation space is small. .
  • connection part 1 when the connection part 1 has a cylindrical structure, insert the aluminum cable into the tube, and then use crimping or welding or applying conductive glue to connect the aluminum cable and the connection part 1 together.
  • the connection is stable and the contact area is large.
  • the electrical connector has good electrical conductivity and mechanical properties, and it is a closed structure, which will not cause cracking or damage of the connection part 1 due to the harsh installation environment, greatly reducing the probability of the connection part 1 and the aluminum cable coming loose, and improving the Connection reliability and service life.
  • the connecting part 1 has a U-shaped opening structure or a V-shaped opening structure
  • the aluminum cable is generally connected by curling and crimping, that is, the U-shaped or V-shaped two sides of the connecting part 1 are curled, flipped, butt-joined and pressed into the aluminum cable.
  • the conductive part of the wire has good electrical conductivity and high mechanical properties because the connecting part 1 is crimped relatively tightly to the aluminum cable, and has a large contact area with the aluminum cable.
  • the connecting part 1 is connected to the conductive part of the aluminum cable by crimping, welding or bonding.
  • the connecting part 1 has a cylindrical structure.
  • the aluminum cable includes a core 41 as a conductive part and an insulating layer 42.
  • the connecting part 1 is connected to the aluminum cable, the insulation at one end of the aluminum cable is The layer 42 is peeled off to expose the wire core 41, and the wire core 41 is installed in the connecting part 1, and then fixed by crimping, welding, or adhesion.
  • Crimping is a production process in which the connecting part 1 is assembled with the conductive part of the aluminum cable, and then the two are stamped into one body using a crimping machine.
  • the advantage of crimping is mass production. By using an automatic crimping machine, products of stable quality can be manufactured quickly and in large quantities.
  • the welding method includes one or more of resistance welding, friction welding, ultrasonic welding, arc welding, laser welding, electron beam welding, pressure diffusion welding, and magnetic induction welding.
  • the contact surface between the connecting part 1 and the conductive part of the aluminum cable is an adhesive layer.
  • the adhesive layer is a sticky material made of thermally conductive material.
  • the connecting part 1 and the conductive part of the aluminum cable are bonded through the adhesive layer. Together.
  • the conductive part of the aluminum cable is a solid aluminum conductor
  • the connecting part 1 is integrally formed with the solid aluminum conductor.
  • the conductive part of the aluminum cable is a solid aluminum conductor.
  • the connection part 1 is integrally formed with the solid aluminum conductor, which simplifies the processing and installation steps and eliminates the need for the connection between the connection part 1 and the aluminum cable. The connection process improves the connection strength.

Abstract

本申请公开了一种新型铝端子，所述铝端子电连接铝制线缆和用电装置并起到导通电流的作用，所述铝端子包括连接部和功能部，所述连接部与所述铝制线缆的导电部分连接，所述功能部与所述用电装置连接，所述功能部的材质为铝，所述功能部上设置至少一个通孔，所述通孔内设置嵌件，所述通孔与所述嵌件之间至少部分通过过渡连接层连接。本申请的新型铝端子可以替代目前常见的铜质材料制作成接线端子，在电气连接领域，可以有效解决铜端子和铝线直接接触发生电化学腐蚀的问题，提高接线端子的使用寿命。

Description

一种新型铝端子
相关申请
本申请要求于2022年9月16日递交的申请号为202211129795.7的中国专利申请的优先权，并引用上述专利申请公开的内容作为本申请的一部分。
技术领域
本申请涉及电气连接领域，更具体地，涉及一种新型铝端子。
背景技术
随着电连接端子的使用量越来越大，铜端子成为了常采用的一种连接线端子，而且，为了实现线缆的轻量化，人们采用铝、铝合金等存储量相对较大且质量相对比较轻的导电性材料作为线缆导体材料，但是，由于铜铝之间的电极电位差较大，当铜端子与铝线缆的导体直接连接后，在空气和水的作用下，铜铝之间会产生电化学腐蚀，铝线缆导体易受腐蚀而导致铜铝连接区域的接触电阻增大，在长期使用过程中，容易引起停电事故，严重时可能会烧毁设备，引起爆炸或火灾，影响电力系统正常运作。
因此，电气连接领域急需一种能够减缓铜铝之间电化学腐蚀，延长电连接结构的使用寿命的新型铝端子。
发明内容
本申请提供了一种能够减缓铜铝之间电化学腐蚀的新型铝端子，所述铝端子用于电连接铝制线缆和用电装置并用于导通电流，所述铝端子包括连接部和功能部，所述连接部与所述铝制线缆的导电部分连接，所述功能部与所述用电装置连接；至少所述功能部的材质为铝，所述功能部上设置至少一个通孔，所述通孔内设置嵌件，所述通孔与所述嵌件之间至少部分通过过渡连接层连接。
可选地，所述过渡连接层为设置在所述嵌件上的镀层。
可选地，所述过渡连接层的成分含有铁、碳、镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
可选地，所述过渡连接层中包含不少于6wt％的铝基固溶体。
可选地，所述过渡连接层中包含不大于46.6wt％的铝基化合物。
可选地，所述嵌件的材质为金属，所述过渡连接层在所述嵌件与所述功能部的至少部分连接面用焊接方式形成的。
可选地，所述焊接方式为激光焊接或搅拌摩擦焊接或压力焊接或超声波焊接或电磁焊接。
可选地，所述嵌件突出于所述功能部的表面。
可选地，所述嵌件上设置安装孔。
可选地，所述安装孔与所述通孔轴向重合或平行。
可选地，所述通孔为阶梯孔，所述嵌件的外周设置阶梯台，所述阶梯台与所述阶梯孔匹配安装。
可选地，所述嵌件的外周设置阶梯台，所述阶梯台的较小尺寸一侧与所述通孔匹配安装。
可选地，所述嵌件为两个，两个所述嵌件外周设置相对的阶梯台，所述阶梯台的较小尺寸一侧分别从所述通孔两侧与所述通孔匹配安装。
可选地，所述嵌件上设置安装螺柱。
可选地，所述安装螺柱与所述通孔轴向重合或平行。
可选地，所述嵌件与所述安装螺柱一体成型。
可选地，所述嵌件的径向尺寸大于所述安装螺柱的直径。
可选地，所述过渡连接层的横截面形状为三角形、四边形、锥形、抛物线形或半楔形。
可选地，所述过渡连接层的横截面沿从所述嵌件到所述功能部方向上，最宽位置的宽度为0.01mm-5mm。
可选地，所述连接部和所述功能部一体成型。
可选地，所述连接部为平板状结构或筒状结构或U型开口结构或V型开口结构。
可选地，所述连接部与所述铝制线缆的导电部分采用压接或焊接或粘接或铆接的方式连接。
可选地，所述铝制线缆的导电部分为实心铝导体，所述连接部与所述实心铝导体一体成型。
根据本公开的实施例，利用本申请的新型铝端子替代目前常见的铜质材料制作成接线端子，在电气连接领域，可以降低端子成本，减轻端子的重量，并且能够有效解决铜端子和铝线直接接触发生电化学腐蚀的问题，提高接线端子的使用寿命。
在铝基材的基础上增加了金属材质的嵌件，并且由嵌件与用电装置连接，既能解决铝基材材质较软，容易变形的问题，又能减缓铝基材与用电装置之间的电化学腐蚀，延长铝端子的使用寿命。
在嵌件与铝基材之间设置过渡连接层，过渡连接层材质选用电势在铜电势与铝电势之间的材料，可以有效的减缓铜铝之间的电化学腐蚀，在电气连接领域，可以有效解决嵌件和铝基材直接接触发生电化学腐蚀的问题，提高铝端子的使用寿命。
通过以下参照附图对本申请的示例性实施例的详细描述，本申请的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本申请的实施例，并且连同其说明一起用于解释本申请的原理。
图1为本申请第一种实施方式的铝端子的剖视图；
图2为本申请第二种实施方式的铝端子的剖视图；
图3为本申请第三种实施方式的铝端子的剖视图；
图4为本申请第四种实施方式的铝端子的剖视图。
图中标示如下：
1、连接部；2、功能部；21、嵌件；22、过渡连接层；3、通孔；41、线芯；42、绝缘层。
具体实施方式
现在将参照附图来详细描述本申请的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本申请及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
本申请提供一种新型铝端子，铝端子用于电连接铝制线缆和用电装置并起到导通电流的作用，铝端子包括连接部1和功能部2，连接部1与铝制线缆的导电部分连接，功能部2与用电装置连接，功能部2的材质为铝或铝合金，功能部2上设置至少一个通孔3，通孔3内设置嵌件21，通孔3与嵌件21之间至少部分通过过渡连接层22连接。
根据本申请的新型铝端子，如图1-图4所示，包括连接部1和材质为铝或铝合金的功能部2，将连接部1与铝制线缆的导电部分连接，将功能部2与用电装置连接，并在功能部2 上设置至少一个通孔3，通孔3内设置嵌件21，通孔3与嵌件21之间至少部分通过过渡连接层22连接。利用本申请的新型铝端子替代目前常见的铜质材料制作成接线端子，在电气连接领域，可以降低端子成本，减轻端子的重量，可以有效解决铜端子和铝线直接接触发生电化学腐蚀的问题，提高接线端子的使用寿命。
在铝基材的基础上增加了金属材质的嵌件，并且由嵌件21与用电装置连接，既能解决铝基材材质较软，容易变形的问题，又能减缓铝基材与用电装置之间的电化学腐蚀，延长铝端子的使用寿命。
在嵌件21与铝基材之间设置过渡连接层22，过渡连接层22材质选用电势在铜电势与铝电势之间的材料，可以有效的减缓铜铝之间的电化学腐蚀，在电气连接领域，可以有效解决嵌件21和铝基材直接接触发生电化学腐蚀的问题，提高铝端子的使用寿命。
在一些实施例中，过渡连接层22为设置在嵌件21上的镀层。过渡连接层22设置为嵌件21上的镀层可以提高铝端子的耐腐蚀性，同时过渡连接层22材质选用电势在铜电势与铝电势之间的材料，可以有效的减缓铜铝之间的电化学腐蚀，在电气连接领域，可以有效解决嵌件21和铝基材直接接触发生电化学腐蚀的问题，提高铝端子的使用寿命。
在一些实施例中，过渡连接层22的成分为铁、碳、镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种。为了论证不同镀层材质对端子耐腐蚀性的影响，发明人使用相同规格、材质及其所在位置镀层材质不同的铝端子样件放到盐雾喷淋试验箱内，对铝端子样件的各个位置喷淋盐雾，每隔20小时取出清洗观察表面腐蚀情况，即20小时为一个周期，直到铝端子样件表面腐蚀面积大于总面积的10％时，停止测试，并记录当时的周期数。在本实施例中，周期数小于80次认为不合格。
表1：不同过渡连接层材质对铝端子耐腐蚀性的影响
从上表1可以看出，当选用过渡连接层22的材质为金、银、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金时，实验结果超过标准值较多，性能比较稳定。当选用过渡 连接层22材质为镍、锡、锡铅合金、锌时，实验结果也是能够符合要求的，因此，发明人选择过渡连接层22材质含有铁、碳、金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
在一些实施例中，过渡连接层22中包含不少于6wt％的铝基固溶体。在纯铝中加入合金元素，形成铝基固溶体，导致晶格畸变，阻碍位错运动，起到固溶体强化作用，提高铝基固溶体的强度，根据合金化的一般规律，当形成无限大固溶体或高浓度固溶体合金时，不仅具有较高的强度，而且具有良好的塑性和良好的压力加工性能。铝-铜、铝-镁、铝-硅、铝-锌、铝-锰等二元合金一般能形成有限的固溶体，具有很高的极限溶解性，固溶强化效果好。另外，嵌件21与功能部2的材料之间的较高的电势差会被铝基固溶体间隔开，过渡连接层22中铝基固溶体的含量越高，过渡连接层22的电势越趋近于嵌件21与功能部2的材料电势之间，从而能够降低嵌件21与功能部2之间的电势差，减缓嵌件21与功能部2之间的电化学腐蚀。
为了论证不同含量铝基固溶体的过渡连接层22对嵌件21和功能部2之间拉拔力和电压降的影响，发明人经过多次试验，考察了不同含量铝基固溶体的过渡连接层22的嵌件21和功能部2之间的拉拔力和电压降，结果参见表2。
表2铝基固溶体在过渡连接层22中的占比对嵌件21和功能部2之间拉拔力和电压降的影响
从上表2可以看出，当过渡连接层22包含的铝基固溶体小于6wt％时，嵌件21和功能部2之间的拉拔力逐步降低，嵌件21和功能部2之间的电压降逐步上升，无法满足铜铝复合端子的力学性能和电气性能要求。随着过渡连接层22包含的铜铝固溶体占比逐渐增多，铝端子的力学性能和电气性能逐渐增强，因此过渡连接层22包含不少于6wt％的铝基固溶体。
在一些实施例中，过渡连接层22中包含不大于46.6wt％的铝基化合物。如果添加到铝中的合金元素的量超过极限溶解度，则当加热固溶处理时，出现不能溶解在固溶体中的第二相的一部分，其被称为过剩相。在铝合金中，这些过量通常是硬且脆的金属间化合物。它们阻碍了合金中的位错运动并强化了合金，这被称为过相强化。此时过渡连接层22的脆性增加，不利于嵌件21与功能部2之间的力学性能。另外，过渡连接层22中金属间化合物的含量越 多，由于金属间化合物的导电性较差，嵌件21与功能部2之间的电阻就越大，从而降低了嵌件21与功能部2之间的电学性能。
为了论证不同含量铝基化合物的过渡连接层22对嵌件21和功能部2之间拉拔力和电压降的影响，发明人经过多次试验，考察了不同含量铝基化合物的过渡连接层22的嵌件21和功能部2之间的拉拔力和电压降，结果参见表3。
表3铝基化合物在过渡连接层22中的占比对嵌件21和功能部2之间拉拔力和电压降的影响
从上表3可以看出，当过渡连接层22中的铝基化合物的总重量占比从1％逐步增加时，由于铝基化合物的脆性大，电阻率高，因此嵌件21与功能部2之间的拉拔力会逐步减小，电压降会逐步增大。经过大量实验发现，当铜铝混合物中的铜铝化合物的总重量占比在46.6％时，铝端子初始的机械性能和电气性能都能满足要求，当过渡连接层22中的铝基化合物的总重量占比增加时，铝端子机械性能和电气性能都达不到标准要求值，并且性能会越来越低，因此，发明人设定过渡连接层22中的铝基化合物的总重量占比不超过46.6％。
在一些实施例中，嵌件21的材质为金属，过渡连接层22在嵌件21与功能部2的至少部分连接面用焊接方式形成。嵌件21的材质可以选择铁、铜、金、银、镍、锡、锡铅合金、锌、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或其合金，能够增加铝端子的导电性能，并且增强铝端子的硬度，与用电装置连接实现更好的电学性能和机械性能。利用焊接的形式将嵌件21与功能部2的至少部分连接面焊接后会形成过渡连接层22。
在一些实施例中，焊接方式为激光焊接或搅拌摩擦焊接或压力焊接或超声波焊接或电磁焊接。
激光焊接是利用高能量密度的激光束作为热源的一种高效精密焊接方法。
搅拌摩擦焊是指利用高速旋转的焊具与工件摩擦产生的热量使被焊材料局部熔化，当焊具沿着焊接界面向前移动时，被塑性化的材料在焊具的转动摩擦力作用下由焊具的前部流向后部，并在焊具的挤压下形成致密的固相焊缝。
压力焊是对焊件施加压力，使接合面紧密地接触产生一定的塑性变形而完成焊接的方法。
超声波焊接方式，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。
电磁焊接方式，是两个被焊工件在强脉冲磁场作用下，产生瞬间高速碰撞，材料表层在很高的压力波作用下，使两种材料的原子在原子间距离内相遇，从而在界面上形成稳定的冶金结合。是固态冷焊的一种，可以将属性相似或不相似的传导金属焊接在一起。
在一些实施例中，嵌件21突出于功能部2的表面。如图2-图4所示，嵌件21突出于功能部2的表面，可以保证在利用螺栓固定功能部2时螺栓不与功能部2表面接触，防止螺栓与功能部2表面发生电化学反应。
在一些实施例中，嵌件21上设置安装孔。如图2-图4所示，在通孔3内设置嵌件21，通过螺栓固定时将嵌件21和功能部2一同固定，因此，需要在嵌件21上设置安装孔，保证可以利用螺栓固定。
在一些实施例中，安装孔与通孔3轴向重合或平行。如图2所示，在一些使用场景中，利用螺栓通过通孔3将功能部2与用电装置连接，嵌件21上的安装孔需要与通孔3轴向重合或平行。
在一些实施例中，通孔3为阶梯孔，嵌件21外周设置阶梯台，阶梯台与阶梯孔匹配安装。在一些实施方式中，嵌件21与功能部2表面平齐时，在嵌件21外周设置阶梯台，如图2-图3所示，对应的将通孔3设置为阶梯孔，保证嵌件21端部的横截面积大于其他部分的横截面积，可以保证端部与功能部2表面平齐，使功能部2不与螺栓接触，并能节约嵌件21的材料。
在一些实施例中，嵌件21为两个，两个嵌件21外周设置相对的阶梯台，阶梯台的较小尺寸一侧分别从通孔3两侧与通孔3匹配安装。如图4所示，上下两个嵌件21在通孔3内相对设置，阶梯台的尺寸较小一侧分别从通孔3的两侧与通孔3匹配安装，两个嵌件21的设置可以保证功能部2从通孔3的两个方向均能安装螺栓，功能部2上下表面均不会与螺栓的端部接触。
在一些实施例中，嵌件21上设置安装螺柱。在一些实施方式中，嵌件21上设置安装螺柱，便于直接将铜铝端子与用电装置连接。
在一些实施例中，安装螺柱与通孔3轴向重合或平行。通过安装螺柱将铜铝端子与用电装置连接，需要保证安装螺柱与通孔3轴向重合或平行。
在一些实施例中，嵌件21与安装螺柱一体成型。将安装螺柱与嵌件21一体成型构造，加工便捷，还可以保证在铜铝端子安装过程中安装螺柱不易丢失，直接与用电装置连接简化安装步骤。
在一些实施例中，嵌件21的径向尺寸大于安装螺柱的直径。由于安装螺柱需要伸入嵌件21中将嵌件21和功能部2一同与用电装置连接，因此设置嵌件21的径向尺寸大于安装螺柱的直径。
在一些实施例中，过渡连接层22的横截面形状为三角形、四边形、锥形、抛物线形或半楔形。如图1-图4所示，过渡连接层22的横截面为三角形。过渡连接层22可以通过不同的焊接方式形成不同形状的横截面，也就是焊缝，合理的设置焊缝的形状，可以增加连接部1与功能部2的连接强度和导电性能。
在一些实施例中，过渡连接层22的横截面沿从嵌件21连接部1到功能部2方向上，最宽位置的宽度为0.01mm-5mm。为保证过渡连接层22可以将嵌件21和通孔3连接，过渡连接层22的最宽位置的宽度不能小于0.01mm，过窄的过渡连接层22可能导致连接部1和功能部2之间的连接强度不高，导致嵌件21在使用过程中与功能部2脱离；同时，发明人经过反复试验验证得出，过大的过渡连接层22并不会增加连接部1和功能部2之间的连接强度，反而为了形成过大的过渡连接层22，需要更大的焊接能量，会使过渡连接层22中产生较多的铜铝化合物，从而影响铝端子的导电性能，因此，过渡连接层22的最宽位置的宽度不得大于5mm。
在一些实施例中，连接部1和功能部2一体成型。连接部1和功能部2一体成型，可以节省加工步骤，提高端子强度。
在一些实施例中，连接部1为平板状结构或筒状结构或U型开口结构或V型开口结构。如图1和图4所示，分别为U型开口结构和筒状结构的连接部1，将连接部1设计成不同形状，使铝端子可以根据实际需求采用不同的连接方式连接铝制线缆，还优化了电气产品工艺结构，减少加工时间，降低了生产运行成本。
连接部1为平板状结构时，其一般采用焊接或者采用导电胶的方式连接铝制线缆，由于连接部1与铝制线缆的连接区域的体积较小，适用于安装空间较小的情形。
或者，连接部1为筒状结构时，将铝制线缆插入筒中，然后采用压接或焊接或者涂导电胶的方式将铝制线缆和连接部1连接在一起，连接稳固，接触面积大，电气接头的导电性能和力学性能较好，而且是封闭结构，不会因安装环境的恶劣造成连接部1开裂或破损，大大降低了连接部1与铝制线缆松脱的几率，提高了连接的可靠度以及使用寿命。
或者，连接部1为U型开口状结构或V型开口状结构时，一般采用卷曲压接的方式连接铝制线缆，即连接部1的U形或V形两边卷曲翻转对接压入到铝导线的导电部分，由于连接部1压接铝制线缆比较紧密，其与铝制线缆的接触面积大，导电性较好，力学性能高。
在一些实施例中，连接部1与铝制线缆的导电部分采用压接或焊接或粘接的方式连接。如图1所示，连接部1为筒状结构，铝制线缆包括作为导电部分的线芯41和绝缘层42，连接部1与铝制线缆连接时，将铝制线缆一端的绝缘层42剥除露出线芯41，将线芯41安装在连接部1内，再通过压接或焊接或粘接的方式固定。
压接方式，压接是将连接部1与铝制线缆的导电部分装配后，使用压接机，将两者冲压为一体的生产工艺。压接的优点是量产性，通过采用自动压接机能够迅速大量的制造稳定品质的产品。
焊接方式，焊接方式包括电阻焊接、摩擦焊接、超声波焊接、弧焊、激光焊接、电子束焊接、压力扩散焊接、磁感应焊接的一种或多种。
粘接方式，连接部1与铝制电缆的导电部分接触面为粘贴层，粘贴层为导热材料制作的带有粘性的材料，通过粘贴层将连接部1与铝制电缆的导电部分粘接在一起。
在一些实施例中，铝制线缆的导电部分为实心铝导体，连接部1与实心铝导体一体成型。在一些使用场景中，铝制线缆的导电部分为实心铝导体，此时，连接部1与实心铝导体一体成型，简化加工和安装步骤，并能省去连接部1与铝制线缆的连接工序，提高连接强度。
虽然已经通过例子对本申请的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了限制本申请的范围。本领域的技术人员应该理解，可在不脱离本申请的范围和精神的情况下，对以上实施例进行修改。本申请的范围由所附权利要求来限定。

Claims (23)

  1. 一种新型铝端子，所述铝端子用于电连接铝制线缆和用电装置并用于导通电流，其特征在于，所述铝端子包括连接部和功能部，所述连接部与所述铝制线缆的导电部分连接，所述功能部与所述用电装置连接；至少所述功能部的材质为铝，所述功能部上设置至少一个通孔，所述通孔内设置嵌件，所述通孔与所述嵌件之间至少部分通过过渡连接层连接。
  2. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层为设置在所述嵌件上的镀层。
  3. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层的成分含有铁、碳、镍、镉、锰、锆、钴、锡、钛、铬、金、银、锌、锡铅合金、银锑合金、钯、钯镍合金、石墨银、石墨烯银和银金锆合金中的一种或多种。
  4. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层中包含不小于6wt％的铝基固溶体。
  5. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层中包含不大于46.6wt％的铝基化合物。
  6. 根据权利要求1所述的新型铝端子，其特征在于，所述嵌件的材质为金属，所述过渡连接层在所述嵌件与所述功能部的至少部分连接面用焊接方式形成的。
  7. 根据权利要求6所述的新型铝端子，其特征在于，所述焊接方式为激光焊接或搅拌摩擦焊接或压力焊接或超声波焊接或电磁焊接。
  8. 根据权利要求1所述的新型铝端子，其特征在于，所述嵌件突出于所述功能部的表面。
  9. 根据权利要求1所述的新型铝端子，其特征在于，所述嵌件上设置安装孔。
  10. 根据权利要求9所述的新型铝端子，其特征在于，所述安装孔与所述通孔轴向重合或平行。
  11. 根据权利要求5所述的新型铝端子，其特征在于，所述通孔为阶梯孔，所述嵌件的外周设置阶梯台，所述阶梯台与所述阶梯孔匹配安装。
  12. 根据权利要求5所述的新型铝端子，其特征在于，所述嵌件的外周设置阶梯台，所述阶梯台的较小尺寸一侧与所述通孔匹配安装。
  13. 根据权利要求5所述的新型铝端子，其特征在于，所述嵌件为两个，两个所述嵌件外周设置相对的阶梯台，所述阶梯台的较小尺寸一侧分别从所述通孔两侧与所述通孔匹配安装。
  14. 根据权利要求1所述的新型铝端子，其特征在于，所述嵌件上设置安装螺柱。
  15. 根据权利要求14所述的新型铝端子，其特征在于，所述安装螺柱与所述通孔轴向重合或平行。
  16. 根据权利要求15所述的新型铝端子，其特征在于，所述嵌件与所述安装螺柱一体成型。
  17. 根据权利要求15所述的新型铝端子，其特征在于，所述嵌件的径向尺寸大于所述安装螺柱的直径。
  18. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层的横截面形状为三角形、四边形、锥形、抛物线形或半楔形。
  19. 根据权利要求1所述的新型铝端子，其特征在于，所述过渡连接层的横截面沿从所述嵌件到所述功能部方向上，最宽位置的宽度为0.01mm-5mm。
  20. 根据权利要求1所述的新型铝端子，其特征在于，所述连接部和所述功能部一体成型。
  21. 根据权利要求1所述的新型铝端子，其特征在于，所述连接部为平板状结构或筒状结构或U型开口结构或V型开口结构。
  22. 根据权利要求1所述的新型铝端子，其特征在于，所述连接部与所述铝制线缆的导电部分采用压接或焊接或粘接或铆接的方式连接。
  23. 根据权利要求1所述的新型铝端子，其特征在于，所述铝制线缆的导电部分为实心铝导体，所述连接部与所述实心铝导体一体成型。
PCT/CN2023/118982 2022-09-16 2023-09-15 一种新型铝端子 WO2024056048A1 (zh)

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CN115799855A (zh) * 2022-09-16 2023-03-14 长春捷翼汽车零部件有限公司 一种新型铝端子
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