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WO2018223885A1 - 一种铜端子与铝导线的接头及其磁感应焊接方法 - Google Patents

一种铜端子与铝导线的接头及其磁感应焊接方法 Download PDF

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Publication number
WO2018223885A1
WO2018223885A1 PCT/CN2018/089207 CN2018089207W WO2018223885A1 WO 2018223885 A1 WO2018223885 A1 WO 2018223885A1 CN 2018089207 W CN2018089207 W CN 2018089207W WO 2018223885 A1 WO2018223885 A1 WO 2018223885A1
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WO
WIPO (PCT)
Prior art keywords
aluminum
copper terminal
aluminum wire
copper
metal layer
Prior art date
Application number
PCT/CN2018/089207
Other languages
English (en)
French (fr)
Inventor
王超
Original Assignee
吉林省中赢高科技有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 吉林省中赢高科技有限公司 filed Critical 吉林省中赢高科技有限公司
Priority to JP2020517251A priority Critical patent/JP7465207B2/ja
Priority to CA3065844A priority patent/CA3065844C/en
Priority to MX2019014340A priority patent/MX2019014340A/es
Priority to EP18814403.4A priority patent/EP3637553A4/en
Priority to US16/619,094 priority patent/US11069991B2/en
Publication of WO2018223885A1 publication Critical patent/WO2018223885A1/zh
Priority to ZA2019/08200A priority patent/ZA201908200B/en

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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
    • H01R4/58—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/01—Welding by high-frequency current heating by induction heating
    • 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
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • B23K2101/38—Conductors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/12—Copper or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • 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
    • 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
    • H01R4/183—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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion

Definitions

  • the present invention relates to the field of wire harnesses, and in particular to a joint of a copper terminal and an aluminum wire and a magnetic induction welding method thereof.
  • connection method of the terminal and the wire is mainly crimping, that is, the guiding core of the wire is placed in the connecting piece of the terminal, and the terminal and the wire are mechanically crimped by the terminal crimping die. together.
  • the conventional crimping method cannot solve the electrochemical reaction of aluminum wires and copper terminals over time, resulting in mechanical and electrical properties of copper terminals and aluminum wire joints. decline. Therefore, for the connection of copper terminals and aluminum wire joints, the method of crimping is difficult to be applied in industrial production.
  • Chinese invention patent CN1073478C discloses a method for electromagnetically connecting or soldering at least two metal parts, but the solution still has the following technical problems and technical defects that cannot be solved:
  • an object of the present invention is to provide a method for connecting a copper terminal and an aluminum wire by magnetic induction welding and a joint structure obtained, which can not only achieve welding between copper and aluminum but also make electrical conduction and The mechanical properties are better, and the connection of the terminals of different terminal connection shapes to the aluminum wires can be realized, and further, the preparation can be stabilized, and the preparation efficiency and quality can be improved.
  • a joint of a copper terminal and an aluminum wire the copper terminal being divided into a connecting member and a functional member connected to the connecting member, the aluminum guiding core of the aluminum wire being connected with the connecting member of the copper terminal; preferably, the The aluminum lead extends or does not extend to the functional component.
  • the connecting member is a component that connects the copper terminal and the aluminum wire; the functional component is a fixing area where the copper terminal is connected to the electric device.
  • the joint of the copper terminal and the aluminum wire has a soldering area
  • the soldering area is at least 1% of an area of an area where the aluminum wire and the copper terminal overlap; preferably, the soldering area is at least an aluminum wire and The copper terminals overlap 10% of the area of the area.
  • soldering area refers to a region where the surfaces of both the copper terminal and the aluminum wire are finally connected together.
  • the overlap region refers to a region where the projection of the copper terminal and the aluminum wire coincide.
  • the inventors found that the welding area accounts for the proportion of the area of the overlapping area of the aluminum wire and the copper terminal, and the voltage drop performance and the pull-out performance of the corresponding welded joint are better, when the ratio is less than 1%.
  • the electrical properties and mechanical properties of the joint are significantly reduced. Therefore, the joint area of the joint is at least 1% of the area of the overlapping area of the aluminum wire and the copper terminal; preferably, the welded area of the joint At least 10% of the area of the area where the aluminum wire and the copper terminal overlap.
  • a spacer metal layer is disposed between the aluminum guiding core and the copper terminal.
  • the inventor introduces a scheme of a spacer metal layer, that is, a spacer metal layer is added between the soldering end of the aluminum wire and the copper terminal connecting member, and the electrode potential of the spacer metal layer is in copper and aluminum. Between the, it can also be stable metal gold or silver. After welding, the electrochemical reaction between the copper terminal and the aluminum wire is reduced, thereby extending the service life of the wire harness and reducing the occurrence of accidents such as burning a car.
  • the material of the spacer metal layer is one or a combination of nickel, cadmium, zirconium, manganese, aluminum, tin, titanium, zinc, cobalt, chromium; preferably, the material of the spacer metal layer is A combination of one or more of tin, nickel or zinc.
  • the electrode potential of nickel is -0.250
  • the electrode potential of tin is -0.136
  • the electrode potential of zinc is -0.763, which is between copper and aluminum.
  • the acquisition of nickel, tin and zinc is relatively simple and can be widely applied. In industrial production.
  • the material of the spacer metal layer may also be one or a combination of gold or silver.
  • Gold or silver is very stable in chemical properties and has good electrical conductivity, so it can also be used as a spacer metal layer.
  • the spacer metal layer has a thickness of from 3 ⁇ m to 5000 ⁇ m; preferably, the spacer metal layer has a thickness of from 5 ⁇ m to 1000 ⁇ m.
  • the spacer metal layers are independently provided.
  • the spacer metal layer is attached to the copper terminal or the aluminum lead by electroplating or press plating or electroless plating or arc spraying.
  • the thickness of the spacer metal layer is less than 3 ⁇ m, the copper terminal and the aluminum wire form an atomic collision during magnetic induction welding, and the spacer metal layer is easily broken by the copper terminal and the aluminum wire, so that the copper-aluminum contact causes the spacer metal layer to be absent.
  • the thickness of the spacer metal layer is greater than 5000 ⁇ m, since the conductivity of most of the spacer metal layer is not as good as that of copper-aluminum metal, the thickness is large, which leads to an increase in the voltage drop of the solder joint; The amount of use increases, the cost increases, but the performance is not significantly improved.
  • the spacer metal layer in the present invention is set in a thickness range of 3 ⁇ m to 5000 ⁇ m.
  • the copper terminal is made of copper or a copper alloy; preferably, the connecting member has a flat shape or an arc shape or a wing-shaped opening shape or a circular closed shape or a polygonal closed shape.
  • the copper terminal material is copper or copper alloy, and the functional component is connected with the electric device, and the connecting component is connected with the aluminum wire to function to conduct current and fix the wire harness;
  • the connecting component of the copper terminal may be Flat, curved, wing-shaped opening, circular closed structure or polygonal closed structure;
  • the conductivity of copper is better than that of aluminum, and the hardness is higher than that of aluminum. Therefore, when connecting with the electric device, copper or copper alloy is also used as the terminal material; the shape of the functional part is in accordance with the electric device.
  • the assembly shape is designed, and the connecting member is designed into a suitable shape according to the current size, the space size of the mounting position, and the drawing force after welding.
  • the aluminum wire is a solid aluminum wire or a multi-core aluminum wire; the aluminum wire aluminum core is made of aluminum or aluminum alloy.
  • the present invention also provides the following technical solutions to achieve the technical purpose of the present invention:
  • the S1 further includes the steps of: separately adding a separately disposed spacer metal layer between the aluminum lead core and the copper terminal connecting member; preferably, the spacing metal layer and the copper terminal connecting member The distance is 0-10mm; preferably, the distance between the spacer metal layer and the copper terminal connector is 0-3mm;
  • the S2 further includes the step of: soldering the aluminum lead core and the copper terminal connection member and the spacer metal layer together by magnetic induction welding so that the outer surface and the space of the aluminum guide core are spaced apart The inner surfaces of the metal layers are joined, and the outer surface of the spacer metal layer is connected to the surface of the copper terminal connector.
  • the magnetic induction welding apparatus used in the present invention further includes a charging power source, a capacitor, a magnetic induction coil, and a fixture suitable for the terminal and the aluminum wire.
  • the aluminum wire soldering end and the copper terminal connector are 0-10 mm; preferably, the aluminum wire soldering end and the copper terminal connector are 0-3 mm;
  • the inventors found that the soldering effect is better at the above distance. If the actual distance is greater than the above distance, the distance between the welded end of the aluminum wire and the copper terminal connector is far, and the aluminum wire and the copper terminal have been discharged when the collision occurs, and the instantaneous impact speed is insufficient when the contact occurs, which may result in insufficient bonding force;
  • the distance between the welded end of the aluminum wire and the copper terminal connecting member is 0-10 mm, so that the aluminum wire and the copper terminal can be collided by an effective force and a sufficient speed to ensure the combined momentum between the two; preferably,
  • the distance between the welded end of the aluminum wire and the copper terminal connector is 0-3 mm, which makes the bonding effect better.
  • the above-mentioned distance refers to the distance between the respective surfaces of the copper terminal and the aluminum wire which need to be welded during electromagnetic welding. Further, if there are a plurality of distances, in some cases, the distance between the soldering faces between the copper terminals and the aluminum wires is equal, and the distance value is within the above range, which is within the scope of the patent protection. In some cases, the distance between the soldering faces between the copper terminals and the aluminum wires is not equal, and the minimum value among all the distance values is within the above range, which is within the scope of the patent protection.
  • the method further comprises the following steps: when the aluminum guiding core is a multi-core aluminum guiding core, the multi-core aluminum guiding core is subjected to an extrusion molding process.
  • the aluminum wire guide wire should be a multi-strand aluminum wire aluminum core, in order to be a multi-strand aluminum wire aluminum core.
  • Each of the monofilaments disperses the stress generated by the vibration, thereby extending the life of the aluminum wire in a vibrating environment.
  • the use of such a multi-strand aluminum wire aluminum guide core may have its own structural defects, that is, there may be a gap inside the multi-strand aluminum wire aluminum lead core, and these gaps may cause residual inside the multi-strand aluminum wire aluminum guide core. Part of the water and air.
  • the inventor added a process before S1, that is, the multi-strand aluminum wire aluminum core is first subjected to extrusion molding, so that there is no gap between the aluminum wires, thereby eliminating water and air. Ingress, and thus the electrochemical reaction between copper and aluminum due to water and air, causing corrosion between the copper terminal and the aluminum wire to reduce the service life.
  • Another advantageous effect of the above extrusion molding process is that, in the process of extrusion molding, the oxide layer on the surface of the aluminum wire can be simultaneously destroyed, so that no impurities are present between the copper terminal and the aluminum wire, thereby making the welding effect more desirable.
  • the soldering area of the copper terminal and the aluminum wire joint is at least 1% of the area of the overlapping area of the aluminum wire and the copper terminal; preferably, the welding area of the joint is at least the aluminum wire and the copper The terminal overlaps 10% of the area of the area.
  • the inventors of the present invention applied magnetic induction welding technology to the connection of copper terminals and aluminum wires for the first time, and for the first time, an industrial grade method for preparing copper terminals and aluminum wire joints by magnetic induction welding technology was given.
  • the inventor has obtained through many creative experiments, by controlling the distance between the aluminum wire and the copper terminal connector or the spacer metal layer and the copper terminal connector, and by controlling the welding area of the copper terminal and the aluminum wire connector and the aluminum wire
  • the percentage relationship between the area of the area overlapping the copper terminals can have different effects on the welding results.
  • the inventor gave the control range of the above parameters based on the experimental results.
  • a method for preparing copper terminals and aluminum wire joints by the industrial grade by magnetic induction welding technology was given. The above components are impacted at high speed under the action of Lorentz force, reaching the atomic energy level connection, so that the contact is very tightly connected, seamless, and the connection structure is more stable.
  • the copper terminal and the aluminum wire magnetic induction welding method of the invention have the welding parts formed by the magnetic induction welding technology completely fit, effectively reducing the intervention of air and water, thereby prolonging the service life of the copper terminal and the aluminum wire joint. Moreover, the magnetic induction welding does not produce metal compounds in the weld, thereby ensuring the electrical properties and mechanical properties of the wire harness, and the copper terminal and the aluminum wire joint prepared by the method meet the electrical and mechanical performance requirements used in the wire harness industry.
  • the magnetic induction welding method of the copper terminal and the aluminum wire of the invention since the magnetic induction welding does not need to heat the copper terminal and the aluminum wire, the manufacturing cost can be saved; at the same time, since no solder or flux is needed during the welding process, The inert protective gas does not need to be treated after the processing is completed, which can greatly save the material and time cost, improve the preparation efficiency, and reduce the welding cost by 30% compared with the commonly used method; in addition, no salt spray or dust is generated during the magnetic induction welding process. And harmful gases, on the one hand to protect the environment, on the other hand to prevent damage to the staff.
  • the present invention investigated the effects of different spacer metal layer thickness on the electrical and mechanical properties of copper terminals and aluminum wire joints. According to a series of meticulous test results, the thickness range of the spacer metal layer is given, and the use requirements are standardized, thereby further improving the use effect of the industrial grade copper terminal and the aluminum wire joint by the method of the invention.
  • the magnetic induction welding method of the copper terminal and the aluminum wire of the present invention when the plurality of aluminum wire cores are selected, the plurality of aluminum wire cores are first subjected to extrusion molding, so that there is no gap between the aluminum wires, thereby Effectively reduce or avoid the electrochemical reaction between copper and aluminum due to water and air, further improving the service life of copper terminals and aluminum wire joints.
  • FIG. 1 is a schematic structural view of a preferred embodiment of a joint of a copper terminal and an aluminum wire according to the present invention
  • FIG. 2 is a schematic structural view of another preferred embodiment of a joint of a copper terminal and an aluminum wire according to the present invention
  • FIG. 3 is a schematic structural view of a copper terminal of the present invention.
  • FIG. 4 is a schematic cross-sectional view of a terminal at a certain stage in a process of magnetic induction welding in a copper terminal of FIG. 1 using a multi-strand aluminum wire core;
  • Figure 5 is a schematic cross-sectional view showing the terminal of the same stage as that of Figure 4 using a solid aluminum conductor
  • 6a and 6b are schematic diagrams showing the distance between the copper terminal and the aluminum wire
  • This embodiment is one of the preferred embodiments of the joint of the copper terminal and the aluminum wire of the present invention.
  • the copper terminal is divided into a connecting member 12, and a functional member 11 connected to the connecting member, and the aluminum guiding core of the aluminum wire 21 is connected with the connecting member of the copper terminal; preferably, the The aluminum lead extends or does not extend to the functional component.
  • the copper terminal is made of copper or a copper alloy; preferably, the aluminum wire aluminum core is made of aluminum or aluminum alloy.
  • the aluminum wire is a multi-core aluminum wire.
  • the aluminum wire may also be a solid aluminum wire, as shown in FIG. 2 .
  • the shape of the connector is flat or arcuate or wing-shaped or round-closed or polygonal closed; in some specific mounting arrangements, copper terminals and aluminum are required.
  • the wire avoids the interference position, so the shape of the connector of the terminal is designed according to the special condition of the cable installation to facilitate the cable installation and avoid interference between the cable and other components.
  • the joint of the copper terminal and the aluminum wire has a soldering area, and the soldering area is at least 1% of an area of the overlapping area of the aluminum wire and the copper terminal; preferably, the soldering The area of the area is at least 10% of the area of the area where the aluminum wire and the copper terminal overlap.
  • the inventors provided the following experiment: 120 sets of copper terminals and aluminum wires of the same material and structure were used, divided into 12 groups of 10 sets each, using the same magnetic induction welding machine and tooling, and The same spacing metal Sn, the same spacing metal thickness; in the area of the overlapping area of the same aluminum wire and the copper terminal, welding different welding area areas, comparing different welding areas to the overlapping area of the aluminum wire and the copper terminal The effect of the ratio of the area on the electrical and mechanical properties of the magnetic induction welded joint.
  • the joint area of the joint is at least 1% of the area of the overlapping area of the aluminum wire and the copper terminal; preferably, the welded area of the joint At least 10% of the area of the area where the aluminum wire and the copper terminal overlap.
  • a spacer metal layer is disposed between the aluminum lead and the copper terminal.
  • the material of the spacer metal layer is one or a combination of nickel, cadmium, manganese, zirconium, cobalt, aluminum, tin, titanium, zinc, chromium; preferably, the material of the spacer metal layer is tin, One or a combination of nickel or zinc; preferably, the material of the spacer metal layer is one or a combination of gold or silver.
  • the spacer metal layer has a thickness of from 3 ⁇ m to 5000 ⁇ m; preferably, the spacer metal layer has a thickness of from 5 ⁇ m to 1000 ⁇ m.
  • Tables 2 and 3 the inventors have provided corresponding data support, as shown in Tables 2 and 3 below.
  • the thickness of the spacer metal layer is less than 3 ⁇ m or more than 5000 ⁇ m, the pull-out force and voltage drop performance of the connecting member may be significantly lowered, and thus the thickness of the spacer metal layer is set to 3 ⁇ m to 5000 ⁇ m; preferably, the The thickness of the spacer metal layer is from 5 ⁇ m to 1000 ⁇ m, and the performance of the welded joint is better.
  • the spacer metal layer is independently disposed; or alternatively, the spacer metal layer is attached to the copper terminal or aluminum by electroplating or press plating or electroless plating or arc spraying. On the core.
  • This embodiment is a more preferred embodiment of the magnetic induction welding method of the copper terminal and the aluminum wire of the present invention, which comprises the following steps:
  • FIG. 3 is a schematic structural view of a copper terminal, including a functional component 11 and a connector 12 of an open structure.
  • the connection is made of an open structure, which is simple to machine and easier to produce with automated equipment.
  • FIG. 4 and FIG. 5 the welded end of the aluminum wire 21 after the stripping of the insulating layer is assembled with the copper terminal connecting member 12, and the size of the stripping insulating layer is made larger than the size of the copper terminal connecting member.
  • the distance between the aluminum lead of the aluminum wire and the copper terminal connector is 0-10 mm; preferably, the distance between the aluminum wire soldering end and the copper terminal connector is 0-3 mm.
  • the aluminum wire and the copper terminal from which the insulating layer is removed are placed in the fixture; the start button of the magnetic induction welding device is pressed to charge the capacitor by the charging power source; after the full capacity is set according to the set capacity, the high voltage capacitor is instantaneously discharged, and the high voltage is high.
  • the current passes through the magnetic induction coil to form a high-voltage electromagnetic field in the processing region, so that the conductive metal in the electromagnetic field is struck at a speed of 300-700 m/s under the action of Lorentz force for 30-100 ⁇ s, at the atomic level.
  • the fusion occurs underneath to achieve the connection of the terminals and the aluminum wires.
  • the inventors conducted several experiments on the distance between the aluminum lead and the copper terminal connector of the aluminum wire during the welding process, and found that the difference in the above distance can have different effects on the welding effect.
  • the specific experimental data is as follows:
  • the pull-out force and the voltage drop performance are better, and the welding effect is better.
  • the aluminum lead core 21 is a multi-strand aluminum wire core.
  • the purpose of selecting such a multi-strand aluminum wire core is to distribute the stress generated by the vibration of each monofilament in the multi-strand aluminum wire core in a vibrating environment, thereby prolonging the service life of the aluminum wire in a vibrating environment.
  • the method further includes the following steps: before the S1, the method further comprises the steps of: when the aluminum guiding core is a plurality of aluminum wire aluminum guiding cores, extruding the plurality of aluminum wire aluminum guiding cores Press forming process.
  • the use of such a multi-strand aluminum wire core may have its own structural defects, that is, there may be gaps inside the multi-strand aluminum wire core, and these gaps may cause residual inside the multi-strand aluminum wire core. Part of the water and air.
  • the inventor added a process before S1, that is, the multi-strand aluminum wire core was first subjected to extrusion molding, so that there was no gap between the aluminum wires, thereby eliminating the entry of water and air. In turn, the electrochemical reaction between copper and aluminum due to water and air is avoided, resulting in corrosion between the copper terminal and the aluminum wire to reduce the service life.
  • Another advantageous effect of the above extrusion molding process is that, in the process of extrusion molding, the oxide layer on the surface of the aluminum wire can be simultaneously destroyed, so that the aluminum wire has better electrical conductivity, thereby making the welding effect more desirable.
  • the aluminum lead core 21 can also be solid.
  • a solid aluminum wire can be used, the processing cost is much smaller than that of the aluminum stranded wire, and the solid aluminum wire can be Soldering directly to the connector of the copper terminal, there is no failure of the multi-strand aluminum wire core with the core wire not soldered.
  • the inside is a solid aluminum wire, and there is no oxide film on the surface of the monofilament of the multi-strand aluminum wire core, and the conductive property is better.
  • This embodiment is another preferred embodiment of the magnetic terminal welding method of the copper terminal and the aluminum wire of the present invention and the joint structure formed thereby.
  • the difference between the embodiment and the above embodiment is as follows:
  • the S1 further includes the step of adding a spacer metal layer between the aluminum wire bonding end and the copper terminal connection. Since copper and aluminum belong to different elements, the metal inertness of copper is greater than that of aluminum, and the electrode potential difference between copper and aluminum is large (copper is +0.337, aluminum is -1.662), when two metals are in direct contact, in air and water. Under the action, aluminum will gradually lose electrons and form an electrochemical reaction, which will cause corrosion of the aluminum wire and reduce the service life of the wire harness. In severe cases, the wire harness joint will cause an accident (such as burning a car) due to poor contact. The smaller the electrode potential difference between the metals, the less obvious the electrochemical reaction.
  • the inventors have introduced a scheme of a spacer metal layer, that is, a spacer metal layer is added between the aluminum lead core and the copper terminal connecting member, and the material electrode potential of the spacer metal layer is in copper and aluminum.
  • a spacer metal layer is added between the aluminum lead core and the copper terminal connecting member, and the material electrode potential of the spacer metal layer is in copper and aluminum.
  • the material of the spacer metal layer is one of nickel, cadmium, manganese, zirconium, aluminum, tin, titanium, zinc, cobalt, chromium or a combination thereof.
  • the material of the spacer metal layer is one selected from tin, nickel or zinc or a combination thereof.
  • the electrode potential of nickel is -0.250
  • the electrode potential of tin is -0.136
  • the electrode potential of zinc is -0.763, which is between copper and aluminum.
  • the acquisition of nickel, tin or zinc is relatively simple, and can be widely applied to industrial production.
  • the material of the spacer metal layer may also be one or a combination of gold or silver.
  • Gold or silver is very stable in chemical properties and has good electrical conductivity, so it can also be used as a spacer metal layer.
  • the shape of the spacer metal layer is a sheet shape, an arc shape, a ring shape, a wing shape or a polygonal structure.
  • the spacer metal layer may be independent, or may be attached to the core of the copper terminal or the aluminum wire by electroplating, pressure plating, electroless plating or arc spraying;
  • the spacer metal layer may be attached to the copper terminal or the aluminum lead core by electroplating or press plating or electroless plating or arc spraying, as follows:
  • the method of electroplating the steps are: 1. plating metal at the anode; 2, the substance to be plated is at the cathode; 3. the anode and cathode are connected with an electrolyte solution composed of the plated metal positive ions; 4. passing the direct current After the power supply, the metal of the anode oxidizes (electrons are lost), and the positive ions in the solution are reduced (obtained electrons) at the cathode to form atoms and accumulate on the surface of the cathode.
  • the method of press plating comprises the steps of: 1. stacking two metals to be pressure-welded; 2. applying pressure to fully diffuse the surface to be welded to achieve interatomic bonding; 3. depending on the metal and the pressure source Differently, the welding effect can be improved by increasing the temperature, and the welding time can be shortened.
  • the electroless plating method is a plating method for reducing metal ions in a plating solution into a metal and depositing it on a surface of a part by using a suitable reducing agent without applying an electric current.
  • the arc spraying method is to transport the spacer metal to the arc region and atomize, and spray the workpiece to the surface of the workpiece at a high speed under the action of the compressed gas to form an arc sprayed layer.
  • the inventors fabricated a copper terminal soldering piece with plating protection and a copper terminal soldering piece without plating protection, comparing the mechanical and electrical properties of the two samples; and after 48 hours. After the salt spray experiment, the mechanical and electrical properties of the samples were compared.
  • the inventors found that after the Ni layer is plated on the copper terminal, the pulling force is increased and the voltage drop is decreased, that is, the mechanical and electrical properties after soldering are better than those of the non-plated Ni layer.
  • the copper terminal is plated with a Ni layer, and after 48 hours of salt spray corrosion, the reduction of the pull-out force and the voltage drop performance is significantly smaller than that of the unplated Ni layer. That is to say, the presence of spacer metal is more beneficial for the fabrication of copper terminals and aluminum wire joints using magnetic induction welding, which can improve the mechanical and electrical properties of copper terminals and aluminum wire joints.
  • a spacer metal layer is added between the aluminum lead and the copper terminal connector; preferably, the distance between the spacer metal layer and the copper terminal connector is 0-10 mm; preferably, the spacer metal layer The distance between the copper terminal connector and the copper terminal connector is 0-3 mm.
  • the inventors have found that when the distance between the spacer metal layer and the copper terminal connector is 0-10 mm, the drawing force is high and the voltage drop is low, and the welding effect is in accordance with mechanics and electricity. Performance requirements. When the distance between the spacer metal layer and the copper terminal connecting member is 0-3 mm, the above effect is more remarkable as shown in the table.

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Abstract

本发明公开了一种铜端子与铝导线的接头及其磁感应焊接方法，所述接头的铜端子分为连接件，以及与连接件相连的功能件，所述铝导线的铝导芯与所述铜端子的连接件连接；所述铝导芯延伸或不延伸至所述功能件；所述磁感应焊接方法包括以下步骤：S1，将经剥除绝缘层后的铝导芯与铜端子连接件装配好；S2，使用磁感应焊接的方法将所述铝导线焊接端和所述铜端子连接件焊接在一起。本技术方案不但能够实现铜铝之间的焊接并使得电学性能与力学性能更优，还能实现不同形状的端子连接件的端子与铝导线的连接，并且提高制备效率和质量。

Description

一种铜端子与铝导线的接头及其磁感应焊接方法 技术领域
本发明涉及线束领域，具体地，涉及一种铜端子与铝导线的接头及其磁感应焊接方法。
背景技术
现有线束常用连接技术中，端子和导线的连接方式主要以压接为主，即导线的导芯放入端子的连接件中，使用端子压接模具将端子和导线采用机械的方式压接在一起。然而，对于铜端子和铝导线这种组合，传统的压接方法无法解决铝导线和铜端子随着时间的推移所发生的电化学反应，因而导致铜端子和铝导线接头的力学性能和电学性能下降。所以针对铜端子和铝导线接头的连接，压接的方法难以在工业生产中得到应用。
中国发明专利CN1073478C公开了一种使至少两个金属制件的电磁连接或焊接的方法，但该方案仍存在以下无法解决的技术问题与技术缺陷：
(1)上述专利方法仅适用于筒状结构端子和线缆连接，并不适用其他扁平状或弧状或翼形开口状或圆形闭口状或多边形闭口状的端子的焊接；而对于铜端子和铝导线接头在线束领域使用中，绝大部分为非筒状结构的端子。因此，该专利方法在制作线束行业中的铜端子和铝导线接头有极大的使用局限性。
(2)该技术无法直接应用于铜端子和铝导线接头的制备。该技术是将两种未限定类别的金属焊接在一起，而该专利所述焊接方法无法解决铜和铝焊接，或在线束领域中，铜端子和铝导线焊接的特殊性。铜端子和铝导线之间的直接接触在线束使用环境中会发生电化学腐蚀，随着时间的推移，铜端子和铝导线接头的电阻会升高，电压降升高，拉拔力与撕裂力会降低，因而该技术无法直接应用于铜端子和铝导线接头的制备。
(3)该技术给出的焊接方法无法满足铜端子和铝导线接头的工业级制备要求。因为该技术并没有研究如何控制铜端子与铝导线之间在磁感应焊接中的距离以获取较优或最优电学性能与力学性能的铜端子与铝导线接头；也没有定义铜端子和铝导线接头的焊接区域面积至少为铝导线与铜端子相重叠区域面积的 百分比；而上述参数对于铜端子和铝导线接头通过磁感应焊接方法制备尤为重要。因此，使用上述技术无法满足铜端子和铝导线接头在线束上使用的工业级制备要求。
发明内容
为了克服现有技术的不足，本发明的目的在于提供一种通过磁感应焊接的方式将铜端子和铝导线连接起来的方法及所得的接头结构，不但能够实现铜铝之间的焊接并使得导电与机械性能更优，还能实现不同端子连接部形状的端子与铝导线的连接，进一步地，还能够实现制备稳定，并且提高制备效率和质量。
为解决上述问题，本发明所采用的技术方案如下：
一种铜端子与铝导线的接头，所述铜端子分为连接件和与连接件相连的功能件，所述铝导线的铝导芯与所述铜端子的连接件连接；优选地，所述铝导芯延伸或不延伸至所述功能件。
所述的连接件为铜端子与铝导线连接的部件；所述的功能件为铜端子与用电装置相连接的固定区域。
优选地，所述的铜端子和铝导线的接头具有焊接区域，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的1％；优选地，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的10％。
需要说明的是，所述焊接区域是指，铜端子跟铝导线两者表面最终连接在一起的区域。所述重叠区域是指，铜端子跟铝导线两者投影相重合的区域。
经过多次的实验，发明人发现焊接面积占所述的铝导线与铜端子相重叠区域面积的比例越大，相应的焊接接头的电压降性能和拉拔力性能越好，当比例小于1％的时候，接头的电学性能和力学性能明显下降，因此，所述接头的焊接区域面积至少为所述的铝导线与铜端子相重叠区域面积的1％；优选地，所述接头的焊接区域面积至少为所述铝导线与铜端子相重叠区域面积的10％。
优选地，所述铝导芯和所述铜端子之间设有间隔金属层。
需要说明的是，由于铜跟铝属于不同的元素，铜的金属惰性要大于铝，铜和铝的电极电位差异较大(铜为+0.337，铝为-1.662)，当两种金属直接接触，在空气和水的作用下，铝会逐渐失去电子，形成电化学反应，导致铝导线腐蚀，减少线束的使用寿命，严重时会因为接触不良，线束接头打火引发事故(如烧车)。而由于金属之间电极电位差距缩小，电化学反应的速率得以降低。因此发 明人在本技术方案中，引入了间隔金属层的方案，即在所述铝导线焊接端和所述铜端子连接件之间加入间隔金属层，该间隔金属层材质的电极电位在铜铝之间，也可以是稳定金属金或银。焊接后会减少铜端子和铝导线之间的电化学反应，从而延长线束的使用寿命，减少事故(如烧车)的发生。
进一步优选地，所述间隔金属层的材质是镍、镉、锆、锰、铝、锡、钛、锌、钴、铬中的一种或几种的组合；优选地，间隔金属层的材质是锡、镍或锌中的一种或几种的组合。
需要说明的是，镍的电极电位为-0.250，锡的电极电位为-0.136，锌的电极电位为-0.763，处于铜铝之间；而且，镍、锡和锌的获取较为简单，可大量适用于工业生产。
优选地，间隔金属层的材质还可以是金或银中的一种或组合。金或银化学性能十分稳定，且导电性好，因此也可以作为间隔金属层使用。
进一步优选地，所述间隔金属层的厚度为3μm到5000μm；优选地，所述间隔金属层的厚度为5μm到1000μm。
进一步优选地，所述间隔金属层是独立设置的。
进一步优选地，所述间隔金属层是通过电镀或压镀或化学镀或电弧喷涂的方法附着在铜端子或铝导芯上的。
需要说明的是，如果间隔金属层的厚度小于3μm，磁感应焊接时铜端子和铝导线形成原子级的碰撞，间隔金属层容易被铜端子和铝导线破坏，从而使铜铝接触导致间隔金属层没有起到间隔两种金属的作用；当间隔金属层的厚度大于5000μm，由于大部分间隔金属层材质的导电性不如铜铝金属，厚度大反而导致焊接接头的电压降升高；另外，间隔金属的用量增大，成本增加，但性能没有明显提升。一般来说，当采用电镀、化学镀或电弧喷涂的方式固定间隔金属层，间隔金属层的厚度可以达到3μm到1000μm；当采用压镀或磁感应焊接的方式，间隔金属层的厚度可以达到1000μm到5000μm；因此本发明中的间隔金属层设置在3μm到5000μm的厚度范围内。
优选地，所述铜端子的材质为铜或铜合金；优选地，所述连接件的形状是扁平状或弧状或翼形开口状或圆形闭口状或多边形闭口状。
需要说明的是，所述铜端子材质为铜或铜合金，功能件与用电装置连接，连接件为与铝导线连接，起到导通电流、固定线束的功能；铜端子的连接件可以是扁平、弧形、翼形开口、圆形闭口结构或多边形闭口结构；
需要说明的是，铜的导电性要比铝好，而且硬度要比铝高，因此在与用电装置连接时，还是会选用铜或铜合金作为端子材质；功能件的形状按照与用电装置的装配形状进行设计，连接件根据电流大小，安装位置的空间尺寸，焊接后的拉拔力的要求，设计成适合的形状。
优选地，所述的铝导线为实心铝导线或者多芯铝导线；所述铝导线铝导芯的材质为铝或铝合金。
同时，本发明还提供以下技术方案达到本发明的技术目的：
一种制备如上所述的铜端子和铝导线的接头的磁感应焊接方法，包括以下步骤：
S1：将铝导芯与铜端子连接件装配好，所述铝导芯和所述铜端子连接件之间的距离为0-10mm；优选地，所述铝导芯和所述铜端子连接件之间的距离为0-3mm；
S2：使用磁感应焊接的方法将所述铝导芯和所述铜端子连接件焊接在一起，使得所述铝导芯的外表面与所述铜端子连接件的表面相连接。
优选地，所述S1还包括以下步骤：在上述铝导芯和所述铜端子连接件之间还添加有独立设置的间隔金属层；优选地，所述间隔金属层和所述铜端子连接件的距离为0-10mm；优选地，所述间隔金属层和所述铜端子连接件的距离为0-3mm；
进一步优选地，所述S2中还包括以下步骤：使用磁感应焊接的方法将所述铝导芯和所述铜端子连接件以及间隔金属层焊接在一起，使得所述铝导芯的外表面与间隔金属层内表面相连接，间隔金属层外表面与所述铜端子连接件的表面相连接。
需要说明的是，本发明中所使用的磁感应焊接设备，还包括充电电源、电容器、磁感应线圈、适合端子和铝导线的工装夹具。
上述提到，所述铝导线焊接端和所述铜端子连接件距离为0-10mm；优选地，铝导线焊接端和所述铜端子连接件距离为0-3mm；
经过多次的实验，发明人发现在上述距离时，焊接的效果更佳。如果实际距离大于上述距离，则铝导线焊接端和所述铜端子连接件之间距离较远，铝导线和铜端子碰撞时已放电结束，接触时瞬间撞击速度不够会导致结合力不足；因此当铝导线焊接端和所述铜端子连接件距离为0-10mm，则可以保证铝导线和铜端子在有效的力的作用和足够的速度进行碰撞，保证两者之间的结合动量； 优选地，铝导线焊接端和所述铜端子连接件距离为0-3mm，会使得结合效果更佳。
需要指出的是，上述所讲的距离，是指在电磁焊接时，铜端子和铝导线需要焊接部分的各自表面之间的距离。进一步地，若存在多个距离时，在部分情况下，铜端子和铝导线之间的各焊接面之间的距离是相等的，此时该距离值在上述范围内即属于本专利保护范围以内；在部分情况下，铜端子和铝导线之间的各焊接面之间的距离是不相等的，此时所有距离值之中的最小值在上述范围之内即属于本专利保护范围以内。
进一步优选地，所述S1之前还包括以下步骤：当所述铝导芯是多芯铝导芯时，将所述多芯铝导芯进行挤压成型处理。
需要说明的是，在某些特定的使用环境下，铝导线会处在振动环境中，此时铝导线的导芯要选用多股铝丝铝导芯，为的是多股铝丝铝导芯中的每一根单丝分散振动产生的应力，从而延长铝导线在振动环境的使用寿命。但是，采用这种多股铝丝铝导芯会存在一个自身的结构缺陷，即由于多股铝丝铝导芯内部会存在间隙，而这些间隙会使得在多股铝丝铝导芯内部残存有部分水和空气。为解决此问题，发明人在S1之前加入了一项工序，即先将所述多股铝丝铝导芯进行挤压成型处理，使得铝丝之间不存在间隙，从而排除了水和空气的进入，进而免铜铝之间因为水和空气的原因而产生电化学反应，导致铜端子和铝导线之间发生腐蚀而降低使用寿命。
上述挤压成型处理工序的另外一个有益效果在于，在挤压成型的过程中，能够同时破坏铝丝表面的氧化层，使得铜端子和铝导线之间不存在杂质，从而使得焊接效果更加理想。
进一步优选地，在完成S2步骤后，铜端子和铝导线接头的的焊接区域面积至少为铝导线与铜端子相重叠区域面积的1％；优选地，接头的焊接区域面积至少为铝导线与铜端子相重叠区域面积的10％。
相比现有技术，本发明的有益效果在于：
1、本发明的发明人将磁感应焊接技术第一次有效地应用到铜端子和铝导线的连接中，第一次给出了工业级的通过磁感应焊接技术制备铜端子和铝导线接头的方法。
2、发明人通过多次创造性的实验得出，通过控制铝导线和铜端子连接件或间隔金属层和铜端子连接件的距离，以及通过控制铜端子和铝导线接头的焊接 区域面积与铝导线与铜端子相重叠区域面积的百分比关系，能够对焊接结果产生不同的影响。发明人依据实验结果，给出了上述参数的控制范围，第一次给出了通过磁感应焊接技术工业级制备铜端子与铝导线接头的方法。上述部件在洛伦兹力的作用下高速撞击，达到原子能级的连接，使接触处连接非常紧密，无缝隙，连接结构更加稳定。本发明的铜端子与铝导线磁感应焊接方法，由于磁感焊接技术所成型的焊接处完全贴合，有效减少空气和水的介入，从而延长了铜端子和铝导线接头的使用寿命。而且磁感应焊接在焊缝中不产生金属化合物，从而能够保证线束的电性能和机械性能，使通过本方法制备的铜端子与铝导线接头达到了在线束行业中使用的电学性能与力学性能要求。
3、本发明的铜端子与铝导线磁感应焊接方法，由于磁感应焊接不需要对铜端子和铝导线加热，能够达到节省制造费用的效果；同时，由于在焊接过程中不需使用焊料、助焊剂、惰性保护气体，加工完成后也不需要再处理，能够大大节省用料和时间成本，提高制备效率，对比常用的方法，焊接成本降低30％；另外，在磁感应焊接过程中不产生盐雾、粉尘和有害气体，一方面保护环境，另一方面防止对工作人员造成伤害。
4、本发明的铜端子与铝导线磁感应焊接方法，在所述铝导线焊接端和所述铜端子连接件之间创新性地加入间隔金属层，该间隔金属层的材质电极电位在铜铝之间，也可以是稳定金属金或银。焊接后会有效延迟铜端子和铝导线之间的电化学反应，从而延长铜端子和铝导线接头的使用寿命，有效降低了线束领域中因铜端子与铝导线接头导致的事故发生率。
5、本发明通过一系列创造性的实验，研究了不同的间隔金属层厚度对铜端子和铝导线接头的电学性能与力学性能的影响。并根据一系列缜密的试验结果，给出了间隔金属层的厚度范围，规范了使用要求，进一步地提升了通过本发明方法工业级制备铜端子与铝导线接头的使用效果。
6、本发明的铜端子与铝导线磁感应焊接方法，所述铜端子连接件可以是扁平状，弧状，翼形开口状，圆形闭口状，多边形闭口状结构，涵盖了线束领域中铜端子与铝导线接头的所有使用形状要求，相比现有技术，大大地增强了铜端子与铝导线接头的使用范围。
7、本发明的铜端子与铝导线磁感应焊接方法，在选用多股铝丝导线芯时，先将所述多股铝丝导线芯进行挤压成型处理，使得铝丝之间不存在间隙，从而有效减轻或避免铜铝之间因为水和空气的原因而产生电化学反应，进一步提升 了铜端子和铝导线接头的使用寿命。
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。
附图说明
图1为本发明铜端子与铝导线的接头的较优选实施方式的结构示意图；
图2为本发明铜端子与铝导线的接头的另一种较优选实施方式的结构示意图；
图3为本发明铜端子的结构示意图；
图4为使用多股铝丝导线芯在图1铜端子中通过磁感应焊接的过程中某一阶段的端子横截面结构示意图；
图5为使用实心铝导芯与图4相同阶段的端子横截面结构示意图；
图6a、图6b为铜端子与铝导线之间距离说明示意图；
具体实施方式
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：
实施例1
本实施例是本发明铜端子与铝导线的接头的其中一种优选的实施方式。如图1所示，所述铜端子分为连接件12，以及与连接件相连的功能件11，所述铝导线21的铝导芯与所述铜端子的连接件连接；优选地，所述铝导芯延伸或不延伸至所述功能件。
优选地，所述铜端子的材质为铜或铜合金；优选地，所述铝导线铝导芯的材质为铝或铝合金。
在本实施例中，所述铝导线为多芯铝导线，在其他的实施方式中，所述铝导线还可以是实心铝导线，如图2所示。
在其中一种优选的实施方式中，所述连接件的形状是扁平状或弧状或翼形开口状或圆形闭口状或多边形闭口状；在某些特定的安装布局中，需要铜端子 与铝导线对干涉位置避让，因此会根据线缆安装的特殊情况，对端子的连接件形状进行设计，以方便线缆安装，避免线缆与其他零部件干涉。
在其中一种优选的实施方式中，所述的铜端子和铝导线的接头具有焊接区域，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的1％；优选地，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的10％。
为证明上述优选实施方式的有益效果，发明人提供如下实验：采用120套相同材质和结构的铜端子和铝导线，分为12组，每组10套，使用相同的磁感应焊接机及工装，以及相同的间隔金属Sn，相同的间隔金属厚度；在相同的铝导线与铜端子相重叠区域面积上，焊接不同的焊接区域面积，对比不同的焊接面积占所述的铝导线与铜端子相重叠区域面积的比例对磁感应焊接接头的电学和力学性能的影响。
从下表1数据可以看出，焊接面积占所述的铝导线与铜端子相重叠区域面积的比例越大，相应的焊接接头的电压降性能和拉拔力性能越好，当比例小于1％的时候，接头的电学性能和力学性能明显下降，因此，所述接头的焊接区域面积至少为所述的铝导线与铜端子相重叠区域面积的1％；优选地，所述接头的焊接区域面积至少为所述铝导线与铜端子相重叠区域面积的10％。
表1不同的焊接面积对电压降(mV)和拉拔力(N)的影响
编号 面积比例 电压降(mV) 拉拔力(N)
1 100％ 2.9 2189.7
2 90％ 3.0 2057.6
3 80％ 3.1 1998.5
4 70％ 3.1 1973.6
5 60％ 3.2 1936.8
6 50％ 3.2 1922.1
7 40％ 3.4 1900.5
8 30％ 3.5 1873.7
9 20％ 3.6 1862.3
10 10％ 3.7 1830.6
11 1％ 4.0 1822.5
12 <1％ 4.2 1701.2
在其中一种优选的实施方式中，所述铝导芯和所述铜端子之间设有间隔金属层。
优选地，所述间隔金属层的材质是镍、镉、锰、锆、钴、铝、锡、钛、锌、铬中的一种或几种组合；优选地，间隔金属层的材质是锡、镍或锌中的一种或几种的组合；优选地，间隔金属层的材质是金或银中的一种或组合。
进一步优选地，所述间隔金属层的厚度为3μm到5000μm；优选地，所述间隔金属层的厚度为5μm到1000μm。为说明本技术特征的实施效果，发明人提供了相应的数据支持，如下表2和表3。
表2不同间隔金属层的厚度对连接件拉拔力(N)的影响
Figure PCTCN2018089207-appb-000001
表3不同间隔金属层的厚度对连接件电压降(mV)的影响
Figure PCTCN2018089207-appb-000002
从上表可以看出，当间隔金属层厚度小于3μm或大于5000μm时，连接 件的拉拔力和电压降性能会明显下降，因此间隔金属层厚度设定到3μm到5000μm；优选地，所述间隔金属层的厚度为5μm到1000μm，焊接接头的性能更佳。
为实现上述间隔金属层的设置及其作用，所述间隔金属层是独立设置的；又或者，所述间隔金属层是通过电镀或压镀或化学镀或电弧喷涂的方法附着在铜端子或铝导芯上。
实施例2
本实施例是本发明铜端子与铝导线磁感应焊接方法的一种较优选的实施方式，其包括以下步骤：
S1：将铝导芯与铜端子连接件装配好，所述铝导芯和所述铜端子连接件距离为0-10mm；优选地，所述铝导芯和所述铜端子连接件距离为0-3mm；
S2：使用磁感应焊接的方法将所述铝导芯和所述铜端子连接件焊接在一起，使得所述铝导芯的外表面与所述铜端子连接件的表面相连接。
在S1之前，将铝导线按照端子连接件的尺寸进行绝缘层的去除；然后将剥除绝缘层的铝导线与铜端子的连接部分装配好。如图3所示是铜端子的结构示意图，包括开口结构的功能件11和连接件12。将连接件设为开口结构，加工较为简单，而且更容易采用自动化设备进行生产。然后如图4、图5所示，将经剥除绝缘层后的铝导线21焊接端与铜端子连接件12装配好，剥除绝缘层的尺寸比照所述铜端子连接件的尺寸进行。
所述铝导线的铝导芯和所述铜端子连接件之间的距离为0-10mm；优选地，铝导线焊接端和所述铜端子连接件之间的距离为0-3mm。
接下来，将去除绝缘层的铝导线和铜端子放入工装夹具中；按动磁感应焊接设备的启动按钮，由充电电源向电容器充电；按设定的容量充满电后，高压电容瞬间放电，高压电流经过磁感应线圈，在加工区域形成高压电磁场，使电磁场中的导电金属在洛伦兹力的作用下，在30-100μs的时间内，以300-700m/s的速度发生撞击，在原子能级状态下发生融合，从而实现端子和铝导线的连接。
发明人对焊接过程中，铝导线的铝导芯和铜端子连接件之间的距离与焊接效果进行了多次实验，发现了上述距离的不同对于焊接效果能够产生不同影响。具体的实验数据如下：
表4不同的铝导线的铝导芯和铜端子连接件之间的距离
对连接件拉拔力和电压降的影响
序号 距离(mm) 拉拔力(N) 电压降(mV)
1 0 2027.2 2.8
2 0.5 2351.4 2.8
3 1 2324.8 2.8
4 1.5 2331.5 2.8
5 2 2346.7 2.9
6 2.5 2338.6 2.9
7 3 2308.4 3.0
8 3.5 2215.8 3.6
9 4 2174.7 3.8
10 4.5 2108.6 3.9
11 5 2002.7 4.0
12 5.5 1942.8 4.2
13 6 1927.4 4.5
14 6.5 1903.4 4.6
15 7 1857.4 4.7
16 7.5 1804.6 4.9
17 8 1778.4 5.1
18 8.5 1739.7 5.1
19 9 1718.4 5.2
20 9.5 1678.3 5.3
21 10 1644.2 5.4
22 11 1581.9 6.3
23 12 1532.7 6.4
由上表可知，发明人发现在铝导线焊接端和所述铜端子连接件距离为0-10mm时，拉拔力较高，同时电压降较低，焊接的效果符合铜端子和铝导线接头对力学和电学的性能要求。
进一步地，所述铝导线焊接端和所述铜端子连接件之间的距离为0-3mm时，拉拔力与电压降的性能较好，焊接的效果更佳。
上述提到的距离，在铜端子连接件是非扁平状时，可能出现存在多个距离值的情况，这些距离值之间均相等或存在不相等。下面对这两种情况予以进一步阐述和说明。如图6a所示，是当所述铝导线在铜端子连接件之内，而各个相焊接的表面之间距离相等的情况，即a＝b＝c＝1mm；此时，当a在上述0-10mm的范围之内即符合本专利保护范围；如图6b所示，是当所述铝导线在铜端子连接件之内，而各个相焊接的表面之间距离存在不相等的情况，即例如a≠b≠c的情况；此时，当a＝1mm、b＝4mm、c＝12mm之中的最小值在上述0-10mm的范围之内即符合本专利保护范围。
在其中一种实施方式中，所述铝导芯21是多股铝丝导线芯。选取这种多股铝丝导线芯的作用是在振动使用环境下，多股铝丝导线芯中的每一根单丝分散 振动产生的应力，从而延长铝导线在振动环境的使用寿命。
进一步优选地，所述S1之前还包括以下步骤：所述S1之前还包括以下步骤：当所述铝导芯是多股铝丝铝导芯时，将所述多股铝丝铝导芯进行挤压成型处理。
需要说明的是，采用这种多股铝丝导线芯会存在一个自身的结构缺陷，即由于多股铝丝导线芯内部会存在间隙，而这些间隙会使得在多股铝丝导线芯内部残存有部分水和空气。为解决此问题，发明人在S1之前加入了一项工序，即先将所述多股铝丝导线芯进行挤压成型处理，使得铝丝之间不存在间隙，从而排除了水和空气的进入，进而避免铜铝之间因为水和空气的原因而产生电化学反应，导致铜端子和铝导线之间发生腐蚀而降低使用寿命。
上述挤压成型处理工序的另外一个有益效果在于，在挤压成型的过程中，能够同时破坏铝丝表面的氧化层，使得铝导线导电性能更佳，从而使得焊接效果更加理想。
在另外一种优选的实施方式中，所述铝导芯21还可以是实心的，在非振动环境中，可以采用实心铝导线，加工成本要远远小于铝绞合线，而且实心铝导线可以直接与铜端子的连接件进行焊接，不存在多股铝丝导线芯有芯线未焊接上的不合格。另外，内部为实心铝线，不存在多股铝丝导线芯单丝表面的氧化膜，导电性能更好的技术效果。
实施例3
本实施例是本发明铜端子与铝导线磁感应焊接方法及其形成的接头结构的另一种较优选的实施方式，本实施例与上述实施例的区别在于：
所述S1还包括以下步骤：在所述铝导线焊接端和所述铜端子连接件之间加入间隔金属层。由于铜跟铝属于不同的元素，铜的金属惰性要大于铝，铜和铝的电极电位差异较大(铜为+0.337，铝为-1.662)，当两种金属直接接触，在空气和水的作用下，铝会逐渐失去电子，形成电化学反应，导致铝导线腐蚀，减少线束的使用寿命，严重时会因为接触不良，线束接头打火引发事故(如烧车)。而由于金属之间电极电位差距越小，则电化学反应越不明显。因此发明人在本技术方案中，引入了间隔金属层的方案，即在所述铝导芯和所述铜端子连接件之间加入间隔金属层，该间隔金属层的材质电极电位在铜铝之间，焊接后会减少铜端子和铝导线之间的电化学反应，从而延长线束的使用寿命，减少事故(如 烧车)的发生。
所述间隔金属层的材质为镍、镉、锰、锆、铝、锡、钛、锌、钴、铬中的一种或其组合。
优选地，间隔金属层的材质选用锡、镍或锌中的一种或其组合。
镍的电极电位为-0.250，锡的电极电位为-0.136，锌的电极电位为-0.763，处于铜铝之间；而且，镍、锡或锌的获取较为简单，可大量适用于工业生产。
优选地，间隔金属层的材质还可以是金或银中的一种或组合。金或银化学性能十分稳定，且导电性好，因此也可以作为间隔金属层使用。
所述间隔金属层的形状为片形、弧形、环形、翼形或多边形结构。
所述间隔金属层可以是独立的，也可以通过电镀、压镀、化学镀或电弧喷镀的方法附着在铜端子或铝导线的线芯上；
上述提到，所述间隔金属层可以通过电镀或压镀或化学镀或电弧喷涂的方法附着在铜端子或铝导芯上，具体方法如下：
所述的电镀的方法，其步骤是：1、镀层金属在阳极；2、待镀物质在阴极；3、阴阳极以镀上去的金属的正离子组成的电解质溶液相连；4、通以直流电的电源后，阳极的金属会氧化(失去电子)，溶液中的正离子则在阴极还原(得到电子)成原子并积聚在阴极表层。
所述的压镀的方法，其步骤是：1、将需压焊的两种金属叠放；2、施加压力使待焊表面充分进行扩散而实现原子间结合；3、视金属不同和压力源不同，可以通过增加温度的方法提高焊接效果，缩短焊接时间。
所述的化学镀的方法，是在无外加电流的情况下借助合适的还原剂，使镀液中金属离子还原成金属，并沉积到零件表面的一种镀覆方法。
所述的电弧喷涂的方法，是将间隔金属输送至电弧区域并雾化，并在压缩气体的作用下高速喷涂到工件表面，形成电弧喷涂层。
为证明间隔金属层对磁感应焊接的有益性，发明人制作了有镀层保护的铜端子焊接件，和无镀层保护的铜端子焊接件，对比两种样件的力学和电学性能；以及经过48小时盐雾实验后，对比样件的力学和电学性能。
表5镀Ni层对焊接连接件的性能影响以及对盐雾腐蚀后的性能影响
Figure PCTCN2018089207-appb-000003
Figure PCTCN2018089207-appb-000004
由上表可知，发明人发现在所述铜端子上镀Ni层后，拉拔力有所提升，电压降有所下降，即焊接后的力学和电学的性能比无镀Ni层的性能要好。
进一步地，所述铜端子上镀Ni层，经过48小时的盐雾腐蚀后，拉拔力与电压降性能的降低幅度明显小于未镀Ni层的接头。也就是说，间隔金属的存在对于使用磁感应焊接制作铜端子与铝导线接头更有益，能够提升铜端子和铝导线接头的力学性能与电学性能。铝导芯和所述铜端子连接件之间添加有间隔金属层；优选地，所述间隔金属层和所述铜端子连接件之间的距离为0-10mm；优选地，所述间隔金属层和所述铜端子连接件之间的距离为0-3mm。下面用实验来证明该技术方案的有效性：
表6间隔金属层和所述铜端子连接件距离对焊接连接件的性能影响
序号 距离(mm) 拉拔力(N) 电压降(mV)
1 0 2289.4 2.8
2 0.5 2317.4 2.9
3 1 2327.6 3.0
4 1.5 2344.8 3.0
5 2 2372.7 3.1
6 2.5 2366.8 3.2
7 3 2316.7 3.2
8 3.5 2213.3 3.6
9 4 2188.7 3.7
10 4.5 2149.4 3.8
11 5 2137.6 4.0
12 5.5 2086.4 4.2
13 6 2019.5 4.3
14 6.5 1983.8 4.4
15 7 1924.6 4.5
16 7.5 1873.5 4.6
17 8 1811.9 4.7
18 8.5 1792.7 4.9
19 9 1752.9 5.0
20 9.5 1722.8 5.1
21 10 1691.7 5.2
22 11 1592.1 6.3
23 12 1557.6 6.5
由上表可知，发明人发现在间隔金属层和所述铜端子连接件之间的距离为0-10mm时，拉拔力较高，同时电压降较低，焊接的效果符合对力学和电学的性能要求。而在间隔金属层和所述铜端子连接件之间的距离为0-3mm时，如表所示，上述效果更为显著。
需要指出的是，上段所提到的距离所需注意的内容，可参照与上述发明内容、实施例2以及图6a、图6b所述，在此不再重复。
其余实施方式与上述实施例相同，在此不再累述。
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 (12)

  1. 一种铜端子与铝导线的接头，其特征在于，所述铜端子分为连接件，以及与连接件相连的功能件，所述铝导线的铝导芯与所述铜端子的连接件连接；优选地，所述铝导芯延伸或不延伸至所述功能件。
  2. 根据权利要求1所述铜端子和铝导线的接头，其特征在于，所述的铜端子和铝导线的接头具有焊接区域，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的1％；优选地，所述焊接区域面积至少为铝导线与铜端子相重叠区域面积的10％。
  3. 如权利要求1所述的铜端子与铝导线的接头，其特征在于，所述铝导芯和所述铜端子之间设有间隔金属层。
  4. 如权利要求3所述的铜端子与铝导线的接头，其特征在于，所述间隔金属层的材质是镍、镉、锰、锆、钴、铝、锡、钛、锌、铬中的一种或几种组合；优选地，间隔金属层的材质是锡、镍或锌中的一种或几种的组合；优选地，间隔金属层的材质是金或银中的一种或组合。
  5. 如权利要求3所述的铜端子与铝导线的接头，其特征在于，所述间隔金属层的厚度为3μm到5000μm；优选地，所述间隔金属层的厚度为5μm到1000μm。
  6. 如权利要求3所述的铜端子与铝导线的接头，其特征在于，所述间隔金属层是独立设置的。
  7. 如权利要求3所述的铜端子与铝导线的接头，其特征在于，所述间隔金属层是通过电镀或压镀或化学镀或电弧喷涂的方法附着在铜端子或铝导芯上。
  8. 如权利要求1所述的铜端子与铝导线的接头，其特征在于，所述铜端子的材质为铜或铜合金；优选地，所述连接件的形状是扁平状或弧状或翼形开口状或圆形闭口状或多边形闭口状。
  9. 如权利要求1所述的铜端子与铝导线的接头，其特征在于，所述的铝导线为实心铝导线或者多芯铝导线；所述铝导线铝导芯的材质为铝或铝合金。
  10. 一种制备权利要求如1-9任一所述的铜端子和铝导线的接头的磁感应焊接方法，其特征在于，包括以下步骤：
    S1：将铝导芯与铜端子连接件装配好，所述铝导芯和所述铜端子连接件之间的距离为0-10mm；优选地，所述铝导芯和所述铜端子连接件之间的距离为 0-3mm；
    S2：使用磁感应焊接的方法将所述铝导芯和所述铜端子连接件焊接在一起，使得所述铝导芯的外表面与所述铜端子连接件的表面相连接。
  11. 如权利要求10所述制备铜端子与铝导线接头的磁感应焊接方法，其特征在于，
    所述S1还包括以下步骤：在上述铝导芯和所述铜端子连接件之间还添加有独立设置的间隔金属层；优选地，所述间隔金属层和所述铜端子连接件的距离为0-10mm；优选地，所述间隔金属层和所述铜端子连接件的距离为0-3mm；
    所述S2中还包括以下步骤：使用磁感应焊接的方法将所述铝导芯和所述铜端子连接件以及间隔金属层焊接在一起，使得所述铝导芯的外表面与间隔金属层内表面相连接，间隔金属层外表面与所述铜端子连接件的表面相连接。
  12. 如权利要求10所述制备铜端子与铝导线接头的磁感应焊接方法，其特征在于，所述S1之前还包括以下步骤：当所述铝导芯是多芯铝导芯时，将所述多芯铝导芯进行挤压成型处理。
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JP2020522871A (ja) 2020-07-30
JP7465207B2 (ja) 2024-04-10
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US11069991B2 (en) 2021-07-20
US20200144738A1 (en) 2020-05-07
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