Mold kit, self-piercing engagement method, battery terminal contact assembly, and battery

Abstract

Provided are a mold kit, a self-piercing engagement method, a battery terminal contact assembly, and a battery. The mold kit comprises a first mold and a second mold. A first component is self-pierced into a second component by means of first-stage engagement using the first mold of the mold kit, so as to achieve pre-engagement therebetween; and the first component is further self-pierced into the second component by means of second-stage engagement using the second mold of the mold kit, so that a fixed connecting relationship having high firmness and strong stability is achieved between the first component and the second component. In particular, when the hardness of a material of the first component is equal to or less than that of a material of the second component, a fixed connecting relationship having the above properties can still be achieved between these two components. Moreover, the defects and problems caused by using welding to achieve a fixed connecting relationship between a terminal post and an adapter piece of a battery can be completely eliminated.

Description

Mold kit, self-piercing bonding method, battery terminal contact assembly and battery Technical Field

[0001] This application relates to the structure of a mold for self-piercing engagement between different components, related methods, and products made therefrom, and more specifically to a mold kit, the self-piercing engagement method using the mold kit, and battery terminal contact assemblies and batteries produced therefrom. Background Technology

[0002] Today, batteries such as prismatic batteries are widely used in various fields, including electric vehicles. Typically, the battery top cover assembly includes terminals and adapter plates. As the core conductive connection components of the battery, the terminals and adapter plates together form the current path between the internal electrodes and the external circuit, or between the internal multiple cells. Therefore, the terminals and adapter plates need to be fixedly connected during the battery production and assembly process.

[0003] In existing technologies, the fixed connection between the terminal post and the adapter plate is typically achieved through laser welding or ultrasonic welding. However, both of these welding methods have corresponding problems in practical applications. Specifically, laser welding is unsuitable for welding dissimilar materials, requires high cleanliness and precise fit clearances, and is prone to welding defects (such as insufficient penetration, burn-through, and bursting). Furthermore, welding slag may be generated during the welding process, significantly impacting battery life and safety. Ultrasonic welding, on the other hand, easily creates indentations on the component surface, hindering subsequent welding processes and also potentially generating welding slag, further affecting battery life and safety. Therefore, effectively overcoming the problems associated with welding-based fixed connections between the terminal post and the adapter plate is a pressing issue that needs to be addressed in this field. Summary of the Invention

[0004] This application is made in view of the aforementioned state of the prior art. The inventors of this application have discovered that a self-piercing joining technique (e.g., self-piercing riveting) can be used to achieve a fixed connection between the pole and the adapter plate. Although this can overcome the problems of a fixed connection between the pole and the adapter plate based on welding, since the hardness of the pole material may be equal to or less than the hardness of the adapter plate material (e.g., both parts are made of the same material), the connection between the pole and the adapter plate after achieving self-piercing joining using conventional molds is not strong enough and has poor stability.

[0005] One object of this application is to provide a mold kit that can be applied to self-piercing bonding between different components (especially the material of the piercing component whose hardness is equal to or less than the material of the pierced component), so that the different components are highly secure and stable after self-piercing bonding.

[0006] Another objective of this application is to provide a self-piercing joining method using the above-mentioned mold kit, which enables a fixed connection between different components (especially the material of the piercing component whose hardness is equal to or less than the material of the pierced component), and the fixed connection has a high degree of firmness and strong stability.

[0007] Another objective of this application is to provide a battery terminal contact assembly manufactured using the aforementioned mold kit and piercing bonding method, as well as a battery including the battery terminal contact assembly. This not only overcomes the problems caused by welding described in the prior art, but also enables the realization of a battery terminal contact assembly with high strength and stability in a relatively simple manner, and is also beneficial for large-scale industrial production.

[0008] To achieve the above objectives, the present application may adopt the following technical solutions.

[0009] This application provides a mold kit for a first component to be self-pierced and joined to a second component. The mold kit includes: a first mold including a first support surface for supporting the second component, the first mold having a first recess formed on the first support surface, and the first mold having a first protrusion formed at the center of the first recess, the first recess and the first protrusion being configured to have a rotationally symmetrical structure with respect to a first centerline perpendicular to the first support surface, the uppermost end of the first protrusion being configured to be flush with the first support surface, and the first protrusion being configured to have a shape tapering from the lower side to the upper side; and a second mold including a second support surface for supporting the second component, the second mold having a second recess formed on the second support surface, and the second mold having a second protrusion formed at the center of the second recess, the second recess and the second protrusion being configured to have a rotationally symmetrical structure with respect to a second centerline perpendicular to the second support surface, the uppermost end of the second protrusion being configured to protrude to the upper side of the second support surface, and the second protrusion being configured to have a shape tapering from the lower side to the upper side.

[0010] In one alternative embodiment, the first protrusion includes a first upper surface configured as a curved surface protruding toward the side where the second component is located, and the uppermost end of the first protrusion is the intersection point of the curved surface and the first centerline.

[0011] In one alternative, the first upper surface is constructed as a spherical cap that is rotationally symmetrical with respect to the first centerline.

[0012] In one alternative embodiment, the first protrusion further includes a first side surface, which is configured to include a first inner annular surface and a second inner annular surface. The first inner annular surface is located below the first upper surface and connected to the first upper surface. The first inner annular surface is configured as a frustum of a cone that is rotationally symmetrical with respect to a first center line. The second inner annular surface is located below the first inner annular surface and connected to the first inner annular surface and the first bottom surface of the first recess. The second inner annular surface is configured as a frustum of a cone that is rotationally symmetrical with respect to a first center line.

[0013] In one optional embodiment, in a first cross-section of the first mold including the first centerline, the contour line of the first inner annular surface consists of two straight line segments; and the contour line of the second inner annular surface consists of two circular arc segments, the center of which is located outside the first protrusion. In another optional embodiment, in the first cross-section, the radius of curvature of the circular arc segment corresponding to the contour line of the spherical crown is R1 and the radius of curvature of the circular arc segment corresponding to the contour line of the second inner annular surface is R2, satisfying 3.5 ≥ R2 / R1 ≥ 2.5.

[0014] In one alternative embodiment, in the first cross section, the included angle a1 between the extensions of the two straight line segments corresponding to the contour line of the first inner annular surface satisfies 90 degrees ≥ a1 ≥ 70 degrees.

[0015] In one alternative, the first outer wall of the first recess is configured to have a shape that tapers from the top to the bottom.

[0016] In one alternative embodiment, the first outer wall surface includes a first outer ring surface and a second outer ring surface. The first outer ring surface is located above the first bottom surface of the first recess and is connected to the first bottom surface. The first outer ring surface is configured as a frustum of a cone that is rotationally symmetrical with respect to the first center line. The second outer ring surface is located above the first outer ring surface and is connected to the first outer ring surface. The second outer ring surface is configured as a frustum of a cone that is rotationally symmetrical with respect to the first center line.

[0017] In one alternative embodiment, in the first cross section containing the first center line, the outline of the first outer ring surface consists of two arc segments, the center of which is located within the first recess; and the outline of the second outer ring surface consists of two straight line segments.

[0018] In one alternative embodiment, the second protrusion includes a second upper surface configured as a plane parallel to the second support surface.

[0019] In one alternative embodiment, the second protrusion further includes a second side surface, which includes a third inner ring surface, a fourth inner ring surface, and a fifth inner ring surface. The third inner ring surface is located below and connected to the second upper surface, and is configured as a frustum of a cone that is rotationally symmetrical about the second center line. The fourth inner ring surface is located below and connected to the third inner ring surface, and is configured as a frustum of a cone that is rotationally symmetrical about the second center line. The fifth inner ring surface is located below the fourth inner ring surface and is connected to the fourth inner ring surface and the second bottom surface of the second recess, and is configured as a frustum of a cone that is rotationally symmetrical about the second center line.

[0020] In one alternative embodiment, in the second cross-section of the second mold that includes the second center line, the outline of the third inner ring surface consists of two arc segments, the center of which is located inside the second protrusion; the outline of the fourth inner ring surface consists of two arc segments, the center of which is located outside the second protrusion; and the outline of the fifth inner ring surface consists of two arc segments, the center of which is located outside the second protrusion.

[0021] In one alternative embodiment, in the second cross section, the radius of curvature of the arc segment corresponding to the contour line of the third inner ring surface is R3, the radius of curvature of the arc segment corresponding to the contour line of the fourth inner ring surface is R4, and the radius of curvature of the arc segment corresponding to the contour line of the fifth inner ring surface is R5, satisfying 12≥R5 / R4≥8 and 2≥R4 / R3≥1.

[0022] In one alternative, at least a portion of the second outer wall surface of the second recess is configured as a cylindrical surface.

[0023] In one alternative embodiment, the second outer wall surface includes a third outer ring surface and a fourth outer ring surface. The third outer ring surface is located above and connected to the second bottom surface of the second recess. The third outer ring surface is configured as a frustum of a cone that is rotationally symmetrical about the second center line. The fourth outer ring surface is located above and connected to the third outer ring surface. The fourth outer ring surface is configured as a cylinder that is rotationally symmetrical about the second center line.

[0024] In one alternative embodiment, in the second cross section, the outline of the third outer annular surface consists of two arc segments, the center of which is located within the second concave portion; and the outline of the fourth outer annular surface consists of two straight line segments.

[0025] In one alternative embodiment, the second upper surface is configured as a circular surface with a diameter of DR1, and the opening of the second recess has a diameter of DR2, satisfying DR2 / 2≥DR1≥DR2 / 3.

[0026] In one alternative embodiment, the first bottom surface of the first recess is parallel to the first support surface, the height between the first bottom surface and the first support surface in the vertical direction of the first mold is D1, the second bottom surface of the second recess is parallel to the second support surface, and the height between the second bottom surface and the uppermost end of the second protrusion in the vertical direction of the second mold is D2, satisfying D1>D2.

[0027] This application also provides a self-piercing joining method for a mold kit using any one of the above technical solutions, characterized in that the self-piercing joining method is used to enable the first component to self-pierce and join to the second component.

[0028] In one alternative embodiment, the method includes: a first joining step, wherein the second component is placed on a first support surface of the first mold, the first component is pressed against a portion of the second component aligned with the first recess, and pressure is applied to the first component such that the first component self-pierces into the second component to form an intermediate assembly; and a second joining step, wherein the intermediate assembly is placed on a second support surface of the second mold such that the joined portion of the first component and the second component in the intermediate assembly is located above the second recess, and pressure is applied to the first component such that the first component further self-pierces into the second component to form a joined assembly.

[0029] In one alternative, the first component is made of a first material and the second component is made of a second material, wherein the first material and the second material are the same; or the first material and the second material have similar hardness.

[0030] This application also provides a battery terminal contact assembly, which is manufactured using the mold kit described in any one of the above technical solutions and / or the self-piercing bonding method described in any one of the above technical solutions.

[0031] In one alternative embodiment, the battery terminal contact assembly includes: a terminal post, which serves as the first component; and an adapter piece, which serves as the second component, wherein the terminal post is engaged with the adapter piece.

[0032] In one alternative embodiment, the pole is made of a first material and the adapter is made of a second material, wherein the hardness of the first material is the same as that of the second material; or the hardness of the first material is less than that of the second material.

[0033] In one alternative, the first material is aluminum and the second material is copper; or both the first material and the second material are copper; or both the first material and the second material are aluminum.

[0034] In one alternative embodiment, the pole includes: a first joint portion formed in a hollow cylindrical shape and joined with the adapter piece; a flange portion fixed to the first joint portion; and a second joint portion fixed to the flange portion and located on the opposite side of the first joint portion relative to the flange portion.

[0035] In one alternative, one end of the first joint is connected to the flange, and the thickness of the other end of the first joint gradually decreases in the direction away from the flange, so that the other end of the first joint expands after it is engaged with the adapter piece.

[0036] In one alternative embodiment, the portion of the adapter piece used for engaging with the pole post is formed with a countersunk hole.

[0037] This application also provides a battery, including the battery terminal contact assembly described in any of the above technical solutions.

[0038] By adopting the above technical solution, this application provides a mold kit and a self-piercing joining method using the above mold kit. By utilizing the first stage joining of the first mold of the mold kit, it is beneficial to enable the first component (e.g., the piercing component) to pierce into the second component (e.g., the pierced component) to achieve pre-joining between the two; further utilizing the second stage joining of the second mold of the mold kit, it is beneficial to enable the first component to further pierce into the second component, thereby enabling the first component and the second component to achieve a fixed connection relationship with high strength and stability, especially when the hardness of the material of the first component is equal to or less than the hardness of the material of the second component, it is still possible to achieve a fixed connection relationship with the above-mentioned properties between the two components.

[0039] This application also provides a battery terminal contact assembly and a battery including the battery terminal contact assembly. Since the fixed connection between the terminal post and the adapter plate of the battery terminal contact assembly is achieved using the aforementioned mold kit and self-piercing joining method, the defects and problems arising from achieving the fixed connection between the terminal post and the adapter plate using welding can be completely eliminated. Furthermore, the fixed connection between the terminal post and the adapter plate is highly robust and stable, which is beneficial for large-scale industrial production. Attached Figure Description

[0040] Figure 1A is a front view schematic diagram showing the first mold of the mold kit according to an embodiment of the present application.

[0041] Figure 1B is a top view of the first mold shown in Figure 1A.

[0042] Figure 1C is a schematic cross-sectional view of the first mold in Figure 1A taken along line S1-S1.

[0043] Figure 1D is an enlarged schematic diagram showing region Z1 in Figure 1C.

[0044] Figure 2A is a front view schematic diagram of a second mold of a mold kit according to an embodiment of the present application.

[0045] Figure 2B is a top view of the second mold shown in Figure 2A.

[0046] Figure 2C is a schematic cross-sectional view of the second mold in Figure 2A taken along line S2-S2.

[0047] Figure 2D is an enlarged schematic diagram showing region Z2 in Figure 2C.

[0048] Figures 3A and 3B are illustrative schematic diagrams illustrating a self-piercing joining method using a mold kit according to an embodiment of the present application, wherein the mold kit includes a first mold shown in Figure 1A and a second mold shown in Figure 1B.

[0049] Figure 4A is a perspective view showing an assembly (battery cover) of some components of a battery (e.g., a prismatic battery) according to an embodiment of the present application, including a battery terminal contact assembly according to the present application.

[0050] Figure 4B is a bottom view of the assembly shown in Figure 4A.

[0051] Figure 4C is a schematic diagram showing the exploded structure of the assembly in Figure 4A.

[0052] Figure 4D is a cross-sectional schematic diagram showing a partial structure of the assembly in Figure 4A, where the cross-sectional lines are omitted.

[0053] Figures 4E and 4F are schematic diagrams showing the state of the pole and the rivet block of the assembly in Figure 4A before and after they are joined.

[0054] Figures 4G and 4H are schematic diagrams showing the state of the pole and the adapter plate of the assembly in Figure 4A before and after they are joined.

[0055] Figure 4I is a cross-sectional schematic diagram showing the pole and adapter plate of the assembly in Figure 4A before they are joined together.

[0056] Explanation of reference numerals in the attached drawings: 1. First mold; 1s. First support surface; 1c. First center line; 11. First recess; 111. First outer ring surface; 112. Second outer ring surface; 113. First bottom surface; 12. First protrusion; 121. First upper surface; 122. First side surface; 1221. First inner ring surface; 1222. Second inner ring surface; D11. First axial direction; D12. First radial direction; D13. First circumferential direction; 2. Second mold; 2s. Second support surface; 2c. Second center line; 21. Second recess; 211. Third outer ring surface; 212. Fourth outer ring surface; 213. Second bottom surface; 22. Second protrusion; 221. Second upper surface; 222. Second side surface; 2221. Third inner ring surface; 2222. Fourth inner ring surface; 2223. Fifth inner ring surface; D21. Second axial direction; D22. Second radial direction; D23. Second circumferential direction; W1. First component; W2. Second component; 101. Pole post; 1011 First joint; 1012 Flange; 1013 Second joint; 102 Adapter piece; 1021 Connecting part; 1021c Countersunk hole; 1022 Branch part; 103 Top cover assembly; 1031 Top cover; 1031h1 First side hole; 1031h2 Second side hole; 1031h3 Intermediate hole; 1032 First insulating component; 1032h First connecting hole; 1032c First groove; 1033 Second insulating component; 1033h Second connecting hole; 1033c Second groove; 1034 Explosion-proof valve; 1035 Protective plate; 104 Sealing ring; 105 External insulating component; 106 Riveting block Detailed Implementation

[0057] Embodiments of this application are described below with reference to the accompanying drawings. For ease of understanding, the elements shown in the drawings may include elements expressed differently from actual dimensions and scales. Furthermore, in the detailed description of the embodiments, for the sake of brevity, this specification does not describe all features of the embodiments in detail.

[0058] Unless otherwise defined, the technical or scientific terms used in the claims and description shall have the ordinary meaning understood by those skilled in the art to which this application pertains. The terms "first," "second," and similar words used in the description and claims of this application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The term "and / or" includes any one or more of the terms listed in connection with the application, and all combinations thereof. Words such as "comprising" or "including" indicate that the components or objects preceding "comprising" or "including" encompass the components or objects listed following "comprising" or "including" and their equivalents, and do not exclude other components or objects. Words such as "connected" or "linked" are not limited to physical or mechanical connections, nor are they limited to direct or indirect connections.

[0059] In this application, "approximately" means that the conditions described herein can be considered to be met within a reasonable margin of error recognized by a person skilled in the art, and the following description uses this expression to convey a similar meaning.

[0060] In this application, unless otherwise stated, "axial," "radial," and "circumferential" refer to the direction along the centerline of the corresponding mold in the mold kit according to this application, the radial direction in a circular cross-section perpendicular to the centerline, and the circumferential direction in the aforementioned cross-section, respectively. In the usage state where the mold of the mold kit according to this application is placed on a horizontal plane with its centerline perpendicular to the horizontal plane, "upper side" and "lower side" refer to the upper and lower sides in the axial direction of the corresponding mold in the aforementioned usage state. Furthermore, "top" of each part refers to the uppermost part of that part in the vertical direction; "bottom" of each part refers to the lowermost part of that part in the vertical direction.

[0061] In this application, "frustum surface" does not refer to the side surface of a frustum in a strict geometric sense, but rather includes the side surface of a frustum whose generatrix is ​​a straight line or a curve.

[0062] The following description, in conjunction with the accompanying drawings, illustrates an embodiment of the mold kit according to this application.

[0063] Using the mold kit according to embodiments of this application, a first component W1 (e.g., a piercing component) can be self-pierced and joined to a second component W2 (e.g., a pierced component). As shown in Figures 1A to 1D and Figures 2A to 2D, the mold kit according to embodiments of this application includes a first mold 1 and a second mold 2. There may be no assembly or connection relationship between the first mold 1 and the second mold 2 in the mold kit; instead, they are used in stages during the process of joining the first component W1 and the second component W2 using the mold kit, thereby allowing the first mold 1 and the second mold 2 to cooperate with each other.

[0064] In this embodiment, the first mold 1 can be made of a metal material with sufficiently high hardness. As shown in Figures 1A to 1D, the first mold 1 is formed in a cylindrical shape. However, this application does not limit the specific structure of the first mold 1, as long as the first mold 1 can achieve self-piercing engagement between the first component W1 and the second component W2 under a stable supported state.

[0065] As shown in Figures 1A to 1D, the first mold 1 includes a first support surface 1s (upper side surface) for supporting the second component W2, the first support surface 1s being formed as a plane. The first mold 1 has a first recess 11 formed on the first support surface 1s, the first outer side wall of the first recess 11 defining a circular opening. The first mold 1 has a first protrusion 12 formed at the center of the first recess 11. The first recess 11 and the first protrusion 12 are integrally configured to have a rotationally symmetrical structure with respect to a first centerline 1c perpendicular to the first support surface 1s, the first centerline 1c passing through the first protrusion 12 along a first axial direction D11. Thus, an annular groove structure extending circumferentially along a first circumferential direction D13 is formed by the first recess 11 and the first protrusion 12.

[0066] To enable the desired movement and deformation between the first component W1 and the second component W2 during the self-piercing engagement process, the first protrusion 12 and the first recess 11 have specific structures, surface shapes, and related dimensions. Specifically, the first protrusion 12 is configured to have a shape that tapers from the bottom to the top, that is, the area of ​​the cross-section of the first protrusion 12 perpendicular to the first centerline 1c gradually decreases from the bottom to the top. Further, the outer surface of the first protrusion 12 includes a first upper surface 121 and a first side surface 122, the first side surface 122 being located below the first upper surface 121 and continuous with the first upper surface 121.

[0067] As shown in Figures 1B to 1D, the first upper surface 121 is the surface formed by the uppermost portion (top) of the first protrusion 12. The first upper surface 121 is constructed as a curved surface protruding towards the side (upper side) where the second component W2 is located. The uppermost end of the first protrusion 12 is the intersection point of this curved surface and the first centerline 1c. In this embodiment, the first upper surface 121 is constructed as a spherical cap (part of a sphere) that is rotationally symmetrical with respect to the first centerline 1c. Moreover, the uppermost end of the first protrusion 12 is constructed to be flush with the first support surface 1s along the first axial direction D11. Thus, when the second component W2 is placed on the first support surface 1s and subjected to the pressure of the first component W1, the lever arm from the uppermost end to the position where the first component W1 and the second component W2 abut against each other has a suitable length.

[0068] As shown in Figures 1B to 1D, the first side surface 122 is configured to include a first inner ring surface 1221 and a second inner ring surface 1222 that are continuous with each other. The first inner ring surface 1221 extends continuously along the first circumferential direction D13, and is located below and connected to the first upper surface 121. The first inner ring surface 1221 is configured as a frustum of a cone that is rotationally symmetric with respect to the first center line 1c. As shown in Figures 1C and 1D, in the first cross-section of the first mold 1 including the first center line 1c, the outline of the first inner ring surface 1221 consists of two straight line segments. The second inner ring surface 1222 extends continuously along the first circumferential direction D13, and is located below the first inner ring surface 1221 and is connected to the first inner ring surface 1221 and the first bottom surface 113 (plane) of the first recess 11. The second inner ring surface 1222 is configured as a frustum of a cone that is rotationally symmetric with respect to the first center line 1c. As shown in Figures 1C and 1D, in the first cross section of the first mold 1 containing the first center line 1c, the outline of the second inner ring surface 1222 consists of two arc segments, with the center of each arc segment located outside the first protrusion 12.

[0069] As shown in Figure 1D, in the first cross-section described above, the radius of curvature of the arc segment corresponding to the contour line of the spherical cap is R1, and the radius of curvature of the arc segment corresponding to the contour line of the second inner ring surface 1222 is R2, satisfying 3.5 ≥ R2 / R1 ≥ 2.5. For example, R1 can be 1 mm and R2 can be 2.8 mm. In the first cross-section, the included angle α1 between the extensions of the two straight line segments corresponding to the contour line of the first inner ring surface 1221 satisfies 90 degrees ≥ a1 ≥ 70 degrees. For example, a1 can be 72.78 degrees.

[0070] As shown in Figures 1B to 1D, the first outer wall of the first recess 11 is configured to have a shape that tapers from the top to the bottom, and the first outer wall is located outside the first protrusion 12 in the first radial direction D12. The first outer wall includes a first outer annular surface 111 and a second outer annular surface 112. The first outer annular surface 111 extends continuously along the first circumferential direction D13, and is located above and connected to the first bottom surface 113 of the first recess 11. The first outer annular surface 111 is configured as a frustum of a cone that is rotationally symmetric about the first centerline 1c. As shown in Figures 1C and 1D, in a first cross-section including the first centerline 1c, the outline of the first outer annular surface 111 consists of two arc segments, the centers of which are located within the first recess 11. The second outer annular surface 112 extends continuously along the first circumferential direction D13. The second outer ring surface 112 is located above and connected to the first outer ring surface 111. The second outer ring surface 112 is constructed as a frustum of a cone that is rotationally symmetrical with respect to the first center line 1c. As shown in Figures 1C and 1D, in the first cross-section including the first center line 1c, the outline of the second outer ring surface 112 consists of two straight line segments. Furthermore, the upper end of the first outer wall surface may be chamfered.

[0071] In this embodiment, the second mold 2 can be made of a metal material with sufficiently high hardness. As shown in Figures 2A to 2D, the second mold 2 is formed in a cylindrical shape. However, this application does not limit the specific structure of the second mold 2, as long as the second mold 2 can achieve self-piercing engagement between the second component W2 and the second component W2 under a stable supported state.

[0072] As shown in Figures 2A to 2D, the second mold 2 includes a second support surface 2s (upper side surface) for supporting the second component W2, the second support surface 2s being formed as a plane. The second mold 2 has a second recess 21 formed on the second support surface 2s, the second outer side wall of the second recess 21 defining a circular opening. The second mold 2 has a second protrusion 22 formed at the center of the second recess 21, the second recess 21 and the second protrusion 22 being integrally constructed to have a rotationally symmetrical structure with respect to a second centerline 2c perpendicular to the second support surface 2s, the second centerline 2c passing through the second protrusion 22 along a second axial direction D21. Thus, an annular groove structure extending circumferentially along a second circumferential direction D23 is formed by the second recess 21 and the second protrusion 22.

[0073] To enable the intermediate assembly formed by the first component W1 and the second component W2 to exhibit the desired movement and deformation during the self-piercing engagement process, the second protrusion 22 and the second recess 21 have specific structures, surface shapes, and related dimensions. Specifically, the second protrusion 22 is configured to have a shape that tapers from the lower side to the upper side, that is, the area of ​​the cross-section of the second protrusion 22 perpendicular to the second centerline 2c gradually decreases from the lower side to the upper side. Further, the outer surface of the second protrusion 22 includes a second upper surface 221 and a second side surface 222, the second side surface 222 being located below the second upper surface 221 and continuous with the second upper surface 221.

[0074] As shown in Figures 2B to 2D, the second upper surface 221 is constructed as a plane parallel to the second support surface 2s, and the uppermost point of the second protrusion 22 is any point on this plane. In this embodiment, the second upper surface 221 is constructed as a circular surface that is rotationally symmetrical with respect to the second center line 2c. Moreover, the uppermost point of the second protrusion 22 is constructed to protrude to the upper side of the second support surface 2s. Furthermore, the diameter of the second upper surface 221 is DR1, and the diameter of the opening of the second recess 21 is DR2, satisfying DR2 / 2≥DR1≥DR2 / 3. Thus, when the second component W2 is placed on the second support surface 2s and subjected to the pressure of the first component W1, the lever arm from the uppermost point to the position where the first component W1 and the second component W2 abut against each other has a suitable length.

[0075] As shown in Figures 2B to 2D, the second side surface 222 is constructed to include a third inner ring surface 2221, a fourth inner ring surface 2222, and a fifth inner ring surface 2223 that are continuous with each other. The third inner ring surface 2221 extends continuously along the second circumferential direction D23, and is located below and connected to the second upper surface 221. The third inner ring surface 2221 is constructed as a frustum of a cone that is rotationally symmetrical with respect to the second center line 2c. As shown in Figures 2C and 2D, in the second section of the second mold 2 containing the second center line 2c, the outline of the third inner ring surface 2221 consists of two arc segments, the center of which is located within the second protrusion 22. The fourth inner ring surface 2222 extends continuously along the second circumferential direction D23, and is located below and connected to the third inner ring surface 2221. The fourth inner ring surface 2222 is constructed as a frustum of a cone that is rotationally symmetrical with respect to the second center line 2c. As shown in Figures 2C and 2D, in the second cross-section of the second mold 2 including the second center line 2c, the outline of the fourth inner ring surface 2222 consists of two arc segments, the centers of which are located outside the second protrusion 22. The fifth inner ring surface 2223 extends continuously along the second circumferential direction D23, and is located below and connected to the fourth inner ring surface 2222. The fourth inner ring surface 2222 is constructed as a frustum of a cone that is rotationally symmetrical with respect to the second center line 2c. As shown in Figures 2C and 2D, in the second cross-section of the second mold 2 including the second center line 2c, the outline of the fifth inner ring surface 2223 consists of two arc segments, the centers of which are located outside the second protrusion 22.

[0076] As shown in Figure 2D, in the second cross section described above, the radius of curvature of the arc segment corresponding to the contour line of the third inner ring surface 2221 is R3, the radius of curvature of the arc segment corresponding to the contour line of the fourth inner ring surface 2222 is R4, and the radius of curvature of the arc segment corresponding to the contour line of the fifth inner ring surface 2223 is R5, satisfying 12≥R5 / R4≥8 and 2≥R4 / R3≥1. For example, R3 can be 0.3mm, R4 can be 0.5mm, and R5 can be 5mm.

[0077] As shown in Figures 2B to 2D, at least a portion of the second outer wall of the second recess 21 is constructed as a cylindrical surface, and the second outer wall is located outside the second protrusion 22 in the second radial direction D22. The second outer wall includes a third outer annular surface 211 and a fourth outer annular surface 212. The third outer annular surface 211 extends continuously along the second circumferential direction D23, and is located above the bottom surface of the second recess 21 and connected to the second bottom surface 213 of the second recess 21. The third outer annular surface 211 is constructed as a frustum of a cone that is rotationally symmetric about the second centerline 2c. As shown in Figures 2C and 2D, in the aforementioned second cross-section, the outline of the third outer annular surface 211 consists of two arc segments, the center of which is located in the second recess 21. The fourth outer annular surface 212 extends continuously along the second circumferential direction D23, and is located above the third outer annular surface 211 and connected to it. The fourth outer toroidal surface 212 is constructed as a cylindrical surface that is rotationally symmetric with respect to the second centerline 2c. As shown in Figures 2C and 2D, in the aforementioned second cross-section, the outline of the fourth outer toroidal surface 212 consists of two straight line segments, each extending linearly along the second axial direction D21. Furthermore, the upper end of the second outer wall surface may be chamfered.

[0078] Regarding the dimensional relationship between the first mold 1 and the second mold 2, the following optional scheme can be adopted. The first bottom surface 113 of the first recess 11 is parallel to the first support surface 1s, and the height between the first bottom surface 113 of the first recess 11 and the first support surface 1s in the vertical direction (first axial direction D11) is D1 (see Figure 1D). The second bottom surface 213 of the second recess 21 is parallel to the second support surface 2s, and the height between the second bottom surface 213 of the second recess 21 and the uppermost end of the second protrusion 22 in the vertical direction (second axial direction D21) is D2 (see Figure 2D), satisfying D1>D2. For example, D1 can be 2mm, and D2 can be 1.3mm.

[0079] The following describes the self-piercing joining method using the mold kit described above.

[0080] As shown in Figures 3A and 3B, the self-piercing bonding method is used to self-pierce and bond a first component W1 to a second component W2. In this embodiment, the self-piercing bonding method includes a first bonding step and a second bonding step that can be executed sequentially.

[0081] In the first joining step, as shown in FIG3A, the second component W2 is placed on the first support surface 1s of the first mold 1, the first component W1 is pressed against the part of the second component W2 that is aligned with the first recess 11, and pressure is applied to the second component W2 so that the first component W1 pierces into the second component W2 to form an intermediate assembly.

[0082] In the second joining step, as shown in FIG3B, the intermediate component is placed on the second support surface 2s of the second mold 2, so that the part of the intermediate component that has been joined with the first component W1 and the second component W2 is located directly above the second recess 21. Pressure is applied to the first component W1, so that the first component W1 further penetrates into the second component W2 to form a joining component.

[0083] Thus, by utilizing the first stage engagement (e.g., the first engagement step) of the first mold 1 of the mold kit, it is advantageous for the first component W1 (e.g., the piercing component) to pierce into the second component W2 (e.g., the pierced component) to achieve pre-engagement between the two; further utilizing the second stage engagement (e.g., the second engagement step) of the second mold 2 of the mold kit, it is advantageous for the first component W1 to pierce into the second component W2, thereby enabling the first component W1 and the second component W2 to achieve a fixed connection relationship with high strength and stability, especially when the hardness of the material of the first component W1 is equal to or less than the hardness of the material of the second component W2, it is still possible to achieve a fixed connection relationship with the above-mentioned properties between the two components W1 and W2.

[0084] The following describes the battery according to this application, which includes battery terminal contact assemblies manufactured using the mold kit and / or self-piercing bonding method described above.

[0085] The battery according to this application can be a lithium battery or a prismatic rechargeable battery. The battery can include a battery body and a battery cover, the battery cover being located on top of the battery body and used for electrical connection to the outside, thereby delivering current from the battery to the outside. As shown in Figures 4A to 4I, the battery cover can include an assembled terminal post 101, an adapter piece 102, a cover assembly 103, a sealing ring 104, an external insulator 105, and a riveting block 106. The terminal post 101 and the adapter piece 102 are configured as a self-locking riveting structure forming a cold metal connection through a self-piercing joining method, thereby forming a stable and reliable fixed connection structure between the terminal post 101 and the adapter piece 102, thus forming the battery terminal contact assembly according to this application.

[0086] As shown in Figures 4C and 4I, the pole post 101 serves as the first component W1 employing a self-piercing engagement method, and includes a first engagement portion 1011, a flange portion 1012, and a second engagement portion 1013 fixed to each other. The first engagement portion 1011 is formed into a hollow cylindrical shape and engages with the adapter piece 102. The flange portion 1012 is fixed to the upper end of the first engagement portion 1011, for example, by integral molding, and the flange portion 1012 protrudes radially outward relative to the first engagement portion 1011. This application does not limit the specific configuration of the flange portion 1012, and it can be determined according to actual needs. For example, the flange portion 1012 can adopt a flange structure with a two-stage stepped shape. The second engagement portion 1013 is fixed to the upper end of the flange portion 1012, and the second engagement portion 1013 is located on the opposite side (upper side) of the side where the first engagement portion 1011 is located relative to the flange portion 1012. The second engagement portion 1013 of the terminal post 101, used for electrical connection with the battery body, is configured to form a riveting connection structure with the corresponding riveting block 106, thereby achieving a fixed connection structure with the battery body and thus fixing it to the battery body. The second engagement portion 1013 of the terminal post 101 is integrally configured as a cylindrical stepped structure, which facilitates the formation of a stable riveting connection structure with the corresponding riveting block 106. Therefore, when the terminal post 101 is installed with the adapter piece 102, the second engagement portion 1013 of the terminal post 101 engages with the corresponding riveting block 106 to form a riveting connection structure between them, and engages with the flange portion 1012 of the terminal post 101 to fix the terminal post 101 to the battery body.

[0087] To achieve the aforementioned self-piercing joining method, as shown in Figures 4C and 4I, one end of the first joining portion 1011 is connected to the flange portion 1012, and the thickness of the other end of the first joining portion 1011 gradually decreases in the direction away from the flange portion 1012, with at least a portion of the inner circumferential surface of the first joining portion 1011 inclined relative to the axial direction of the pole post 101. Thus, the first joining portion 1011 of the pole post 101 is formed in a U-shape in a longitudinal section including the centerline of the pole post 101, with a flared end, facilitating self-piercing and, after self-piercing, expanding outwards to form a self-locking riveting structure. Furthermore, the other end of the first joining portion 1011 has a relatively sharp structure, allowing the first joining portion 1011 to penetrate the adapter piece 102 and expand outwards, thereby forming a stable self-locking riveting structure with the adapter piece 102.

[0088] As shown in Figures 4C and 4I, the adapter piece 102 serves as the second component W2 employing a self-piercing bonding method. The adapter piece 102 is bonded to the electrode post 101 via this method, as described above. The adapter piece 102 is integrally formed as a thin sheet and includes a connecting portion 1021 and two branch portions 1022. The connecting portion 1021, which engages with the electrode post 101, has a countersunk hole 1021c. Due to the countersunk hole 1021c, the structural strength of the portion of the connecting portion 1021 where the countersunk hole 1021c is formed is relatively low. Furthermore, the electrode post 101 is made of a first material, and the adapter piece 102 is made of a second material. The hardness of the first material is the same as the hardness of the second material; or the hardness of the first material is less than the hardness of the second material. For example, the first material can be aluminum and the second material can be copper, or both the first and second materials can be copper, or both the first and second materials can be aluminum.

[0089] Furthermore, in order for the first joint 1011 to smoothly self-pierce into the adapter piece 102, the maximum wall thickness t1 of the first joint 1011 is adapted to the material strength (e.g., yield strength) of the adapter piece 102 and the pole post 101, as well as the thickness t2 of the adapter piece 102. To form an effective self-locking riveting structure without material piercing, and considering the different elongation at break of materials under different heat treatment states, the following configuration can be adopted in this solution:

[0090] (1) If the material strength of both the adapter piece 102 and the pole piece 101 is greater than 150 MPa, the maximum wall thickness of the first joint 1011 is t1 = (0.8~1.6)t2;

[0091] (2) If the material strength of both the adapter plate 102 and the pole post 101 is <150MPa, the maximum wall thickness of the first joint 1011 is t1 = (0.6~1.2)t2;

[0092] (3) If the material strength of the adapter piece 102 is <150MPa and the material strength of the pole piece 101 is >150MPa, the maximum wall thickness of the first joint 1011 is t1 = (0.6~1.4)t2.

[0093] In this way, the first joint portion 1011 of the electrode post 101 engages with the connecting portion 1021 of the adapter piece 102. Under external force, the first joint portion 1011, while engaging with the flange portion 1012 of the electrode post 101, penetrates the connecting portion 1021 of the adapter piece 102 and expands outwards in all directions, contacting and pressing the surface of the adapter piece 102. This forms a stable self-locking riveting structure between the electrode post 101 and the adapter piece 102, thus creating a stable and reliable cold metal connection structure between the electrode post 101 and the adapter piece 102 (see Figure 4D). The entire fixing connection process is a cold metal connection, without any hot connection, effectively reducing the cleanliness requirements of the component surfaces. Furthermore, no metal foreign objects are generated during the connection process, thus not affecting the lifespan and safety performance of the lithium battery.

[0094] By adopting the above scheme, as shown in Figures 4A to 4I, the battery cover is provided with two battery terminal contact assemblies, wherein the first battery terminal contact assembly corresponds to the negative terminal and the second battery terminal contact assembly corresponds to the positive terminal. In this embodiment, the first battery terminal contact assembly and the second battery terminal contact assembly are respectively provided at both ends of the battery cover. In the first battery terminal contact assembly, the terminal post 101 and the cover assembly 103 can be fixedly connected by a riveting connection structure, while the terminal post 101 and the adapter piece 102 are fixedly connected by a self-piercing engagement to achieve a self-locking riveting structure. In the second battery terminal contact assembly, the terminal post 101 and the cover assembly 103 can be fixedly connected by a riveting connection structure, while the terminal post 101 and the adapter piece 102 are fixedly connected by a self-piercing engagement to achieve a self-locking riveting structure.

[0095] As shown in Figure 4C, the upper cover assembly 103 includes an assembled upper cover 1031, a first insulating member 1032, a second insulating member 1033, an explosion-proof valve 1034, and a protective plate 1035. The upper cover 1031 is generally rectangular, and its two ends have a first side hole 1031h1 and a second side hole 1031h2 for mounting the first battery terminal contact assembly and the second battery terminal contact assembly. Both side holes 1031h1 and 1031h2 are through holes. To improve the stability of the fixed connection with the first and second battery terminal contact assemblies, the upper cover 1031 forms corresponding recessed mounting groove structures at the locations of the first side hole 1031h1 and the second side hole 1031h2. In this application, the specific structural form of the mounting groove structure is not limited and can be determined according to actual needs. For example, a square mounting groove structure can be used. The upper cover 1031 has a central hole 1031h3 for housing the explosion-proof valve 1034 at its center. This central hole 1031h3 is a through hole, and its shape and size are adapted to the explosion-proof valve 1034 and the protective plate 1035. The explosion-proof valve 1034 is fixed to the central hole 1031h3 on the upper cover 1031 by welding. In this application, the structure of the explosion-proof valve 1034 and its specific welding structure are not limited and can be determined according to actual needs. The protective plate 1035 can be bonded and fixed at the central hole 1031h3 of the upper cover 1031 to cover the explosion-proof valve 1034 and provide protection for it. In this application, the structure and specific arrangement of the protective plate 1035 are not limited and can be determined according to actual needs. At positions corresponding to the first side hole 1031h1 and the second side hole 1031h2 of the upper cover 1031, the first insulating member 1032 and the second insulating member 1033 are respectively provided with corresponding first connecting holes 1032h and second connecting holes 1033h. At positions corresponding to the middle hole 1031h3 of the upper cover 1031, the first insulating member 1032 and the second insulating member 1033 are respectively provided with corresponding first grooves 1032c and second grooves 1033c. The first grooves 1032c and the second grooves 1033c are adapted to fit each other through their shapes, so as to be compatible with the explosion-proof valve 1034. The first insulating member 1032 and the second insulating member 1033 are mutually fitted on the upper cover 1031, and the first connecting hole 1032h of the first insulating member 1032 corresponds to the first side hole 1031h1 of the upper cover 1031, and the second connecting hole 1033h of the second insulating member 1033 corresponds to the second side hole 1031h2 of the upper cover 1031. The first groove 1032c of the first insulating member 1032 cooperates with the second groove 1033c of the second insulating member 1033 to cover the explosion-proof valve 1034 installed in the middle hole 1031h3 of the upper cover 1031.

[0096] Furthermore, as shown in Figures 4C and 4D, the first battery terminal contact assembly, in addition to the terminal post 101 and the adapter piece 102, may also include a sealing ring 104, an external insulating component 105, and a riveting block 106. The overall structure of the terminal post 101 and the adapter piece 102 in the first battery terminal contact assembly is as described above. The terminal post 101 can be made of aluminum or copper, and the adapter piece 102 can be made of copper. The sealing ring 104 in the first battery terminal contact assembly is a T-shaped sealing ring 104, which is adapted to the through hole inside the first insulating component 1032 and can be placed in the through hole. The internal through hole of the sealing ring 104 is adapted to the second joint portion 1013 of the terminal post 101, allowing the second joint portion 1013 to be inserted through it. The overall structure of the external insulating component 105 in the first battery terminal contact assembly is adapted to the mounting groove structure of the upper cover 1031 and can be placed in the mounting groove structure. Furthermore, the external insulating member 105 has a mounting groove adapted to the riveting block 106. A limiting step is formed at the corner of the mounting groove to limit the rivet block 106 circumferentially, ensuring the stability and reliability of the riveting fit between the rivet block 106 and the pole post 101. The external insulating member 105 has a through hole at the bottom of the mounting groove, which is adapted to the second joint portion 1013 of the pole post 101, allowing the second joint portion 1013 to be inserted through. The overall structure of the riveting block 106 is adapted to the mounting groove of the external insulating member 105, allowing it to be placed within the groove. Additionally, a through hole is formed in the middle of the riveting block 106, which is adapted to the second joint portion 1013 of the pole post 101, enabling the formation of a riveting connection structure. When the first battery terminal contact assembly with this structure is assembled and fixed with the upper cover assembly 103, the sealing ring 104 is placed in the first connection hole 1032h of the first insulating member 1032, and the external insulating member 105 is placed in the corresponding mounting groove structure of the upper cover 1031.

[0097] Therefore, as shown in Figures 4D to 4I, the second joint portion 1013 of the first battery terminal contact assembly passes sequentially through the sealing ring 104, the first side hole 1031h1 of the top cover 1031, and the through hole of the external insulating member 105, and is inserted into the through hole of the riveting block 106. In this state, a riveting operation is performed on the second joint portion 1013 of the pole post 101 inserted into the through hole on the riveting block 106, so that a riveting connection structure is formed between the second joint portion 1013 of the pole post 101 and the riveting block 106, thereby sequentially fixing the riveting block 106, the external insulating member 105, the top cover 1031, the first insulating member 1032, the sealing ring 104, and the pole post 101 together. Moreover, the flange portion 1012 of the pole post 101 abuts against the sealing ring 104, forming a sealing structure between the pole post 101 and the first insulating member 1032. For fixing the terminal post 101 to the top cover 1031, the connecting portion 1021 of the adapter piece 102 is correspondingly provided with the first engaging portion 1011 of the terminal post 101. Through riveting, the first engaging portion 1011 can penetrate the connecting portion 1021 of the adapter piece 102 and expand in all directions. The expanded portion forms a pressure on the outer surface of the adapter piece 102, thereby forming a stable self-locking riveting structure between the terminal post 101 and the adapter piece 102 (see Figure 4D). Furthermore, the second battery terminal contact assembly also includes the terminal post 101, the adapter piece 102, the sealing ring 104, the external insulating member 105, and the riveting block 106 assembled together. The structure and assembly process of this second battery terminal contact assembly are the same as those of the first battery terminal contact assembly described above, and will not be repeated here.

[0098] Therefore, in this embodiment, the first battery terminal contact assembly and the second battery terminal contact assembly are fixedly connected to the top cover assembly 103 based on a metal cold connection structure (the expansion riveting connection structure between the terminal post 101 and the riveting block 106). Furthermore, the terminal post 101 and the adapter piece 102 in the first and second battery terminal contact assemblies are fixedly connected based on a self-locking riveting structure using metal cold connection. This entire fixed connection structure completely eliminates the need for thermal connections, effectively ensuring the lifespan and safety performance of the lithium battery.

[0099] It should be understood that the above embodiments are merely exemplary and are not intended to limit this application. Those skilled in the art can make various modifications and changes to the above embodiments under the teachings of this application without departing from the scope of this application. Further, the following supplementary description is provided.

[0100] i. As described in the above specific embodiments, the mold kit includes a first mold 1 and a second mold 2, but this application is not limited thereto. In other alternative embodiments, the mold kit may also include more molds.

[0101] ii. The specific embodiments described above illustrate that certain structures of the first mold 1 and the second mold 2 have specific dimensions, but this application is not limited thereto. In other alternative embodiments, the dimensions of the first mold 1 and the second mold 2 can be changed as needed.

[0102] iii. The above specific embodiments illustrate the use of a mold kit according to this application to join the first component W1 and the second component W2 together via a self-piercing joining method. The first component W1 may be made of a first material, and the second component W2 may be made of a second material. The first material and the second material may be the same, or the first material and the second material may have similar hardness. As long as those skilled in the art consider the two materials to have approximately the same hardness, the condition of the two materials having similar hardness is satisfied.

[0103] It is understood that some of the components, structures, and constituent parts described above may be omitted without affecting the achievement of one or more objectives of this application. Different embodiments, examples, or aspects may be appropriately combined, as long as they do not contradict or conflict with each other.

[0104] The foregoing has described exemplary embodiments and variations of this application; however, it should be understood that various modifications may be made. For example, if the described techniques are performed in a different order and / or if components in the described system, architecture, device, or circuit are combined in different ways and / or replaced or supplemented by other components or their equivalents, achieving the same, similar, or other suitable results, these changes or modifications also fall within the scope of the claims.

Claims

1. A mold kit for a first component (W1) to be self-pierced and joined to a second component (W2), characterized in that, The mold kit includes: A first mold (1) includes a first support surface (1s) for supporting the second component (W2), the first mold (1) having a first recess (11) formed on the first support surface (1s), and a first protrusion (12) formed at the center of the first recess (11), the first recess (11) and the first protrusion (12) being configured as a whole to have a rotationally symmetrical structure with respect to a first centerline (1c) perpendicular to the first support surface (1s), the uppermost end of the first protrusion (12) being configured to be flush with the first support surface (1s), and the first protrusion (12) being configured to have a shape that tapers from the lower side to the upper side; and The second mold (2) includes a second support surface (2s) for supporting the second component (W2), the second mold (2) having a second recess (21) formed on the second support surface (2s), and the second mold (2) having a second protrusion (22) at the center of the second recess (21), the second recess (21) and the second protrusion (22) being configured as a whole to have a rotationally symmetrical structure with respect to a second center line (2c) perpendicular to the second support surface (2s), the uppermost end of the second protrusion (22) being configured to protrude to the upper side of the second support surface (2s), and the second protrusion (22) being configured to have a shape that tapers from the lower side to the upper side.

2. The mold kit according to claim 1, characterized in that, The first protrusion (12) includes a first upper surface (121), which is configured as a curved surface protruding toward the side where the second component (W2) is located, and the uppermost end of the first protrusion (12) is the intersection point where the curved surface intersects with the first center line (1c).

3. The mold kit according to claim 2, characterized in that, The first upper surface (121) is constructed as a spherical cap that is rotationally symmetrical with respect to the first center line (1c).

4. The mold kit according to claim 3, characterized in that, The first protrusion (12) further includes a first side surface (122), which is configured to include a first inner annular surface (1221) and a second inner annular surface (1222). The first inner annular surface (1221) is located below the first upper surface (121) and connected to the first upper surface (121). The first inner annular surface (1221) is constructed as a frustum of a cone that is rotationally symmetrical with respect to the first center line (1c). The second inner ring surface (1222) is located below the first inner ring surface (1221) and is connected to the first bottom surface (113) of the first inner ring surface (1221) and the first recess (11). The second inner ring surface (1222) is constructed as a frustum surface that is rotationally symmetrical with respect to the first center line (1c).

5. The mold kit according to claim 4, characterized in that, In the first section of the first mold (1) that includes the first centerline (1c), The outline of the first inner ring surface (1221) consists of two straight line segments; and the outline of the second inner ring surface (1222) consists of two arc segments, the center of which is located outside the first protrusion (12).

6. The mold kit according to claim 5, characterized in that, In the first cross section, the radius of curvature of the arc segment corresponding to the outline of the spherical crown is R1 and the radius of curvature of the arc segment corresponding to the outline of the second inner ring surface (1222) is R2, satisfying 3.5≥R2 / R1≥2.

5.

7. The mold kit according to claim 5, characterized in that, In the first cross section, the included angle a1 between the extensions of the two straight line segments corresponding to the outline of the first inner annular surface (1221) satisfies 90 degrees ≥ a1 ≥ 70 degrees.

8. The mold kit according to any one of claims 1 to 7, characterized in that, The first outer wall of the first recess (11) is configured to have a shape that tapers from the top to the bottom.

9. The mold kit according to claim 8, characterized in that, The first outer wall surface includes a first outer annular surface (111) and a second outer annular surface (112). The first outer annular surface (111) is located above the first bottom surface (113) of the first recess (11) and is connected to the first bottom surface (113). The first outer annular surface (111) is constructed as a frustum of a cone that is rotationally symmetrical with respect to the first center line (1c). The second outer ring surface (112) is located above the first outer ring surface (111) and is connected to the first outer ring surface (111). The second outer ring surface (112) is constructed as a frustum of a cone that is rotationally symmetrical with respect to the first center line (1c).

10. The mold kit according to claim 9, characterized in that, In the first section containing the first centerline (1c), The outline of the first outer ring surface (111) consists of two arc segments, the center of which is located inside the first recess (11); and the outline of the second outer ring surface (112) consists of two straight line segments.

11. The mold kit according to any one of claims 1 to 7, characterized in that, The second protrusion (22) includes a second upper surface (221) which is configured as a plane parallel to the second support surface (2s).

12. The mold kit according to claim 11, characterized in that, The second protrusion (22) also includes a second side surface (222), which includes a third inner annular surface (2221), a fourth inner annular surface (2222), and a fifth inner annular surface (2223). The third inner annular surface (2221) is located below the second upper surface (221) and connected to the second upper surface (221). The third inner annular surface (2221) is constructed as a frustum of a cone that is rotationally symmetrical with respect to the second center line (2c). The fourth inner annular surface (2222) is located below and connected to the third inner annular surface (2221), which is constructed as a frustum of a cone that is rotationally symmetric with respect to the second center line (2c). The fifth inner ring surface (2223) is located below the fourth inner ring surface (2222) and is connected to the fourth inner ring surface (2222) and the second bottom surface (213) of the second recess (21). The fourth inner ring surface (2222) is constructed as a frustum surface that is rotationally symmetrical with respect to the second center line (2c).

13. The mold kit according to claim 12, characterized in that, In the second section of the second mold (2) that includes the second centerline (2c), The outline of the third inner annular surface (2221) consists of two arc segments, the center of which is located inside the second protrusion (22); The outline of the fourth inner annular surface (2222) consists of two arc segments, the center of which is located outside the second protrusion (22); and The outline of the fifth inner annular surface (2223) consists of two arc segments, the center of which is located outside the second protrusion (22).

14. The mold kit according to claim 13, characterized in that, In the second cross section, the radius of curvature of the arc segment corresponding to the contour line of the third inner ring surface (2221) is R3, the radius of curvature of the arc segment corresponding to the contour line of the fourth inner ring surface (2222) is R4, and the radius of curvature of the arc segment corresponding to the contour line of the fifth inner ring surface (2223) is R5, satisfying 12≥R5 / R4≥8 and 2≥R4 / R3≥1.

15. The mold kit according to claim 11, characterized in that, At least a portion of the second outer side wall of the second recess (21) is configured as a cylindrical surface.

16. The mold kit according to claim 15, characterized in that, The second outer wall surface includes a third outer annular surface (211) and a fourth outer annular surface (212). The third outer annular surface (211) is located above the second bottom surface (213) of the second recess (21) and is connected to the second bottom surface (213). The third outer annular surface (211) is constructed as a frustum of a cone that is rotationally symmetrical with respect to the second center line (2c). The fourth outer ring surface (212) is located above the third outer ring surface (211) and is connected to the fourth outer ring surface (212). The fourth outer ring surface (212) is constructed as a cylindrical surface that is rotationally symmetrical with respect to the second center line (2c).

17. The mold kit according to claim 16, characterized in that, In the second cross section, the outline of the third outer ring surface (211) consists of two arc segments, the center of which is located in the second recess (21); and the outline of the fourth outer ring surface (212) consists of two straight line segments.

18. The mold kit according to claim 11, characterized in that, The second upper surface (221) is constructed as a circular surface with a diameter of DR1, and the diameter of the opening of the second recess (21) is DR2, satisfying DR2 / 2≥DR1≥DR2 / 3.

19. The mold kit according to any one of claims 1 to 7, characterized in that, The first bottom surface (113) of the first recess (11) is parallel to the first support surface (1s), and the height between the first bottom surface (113) and the first support surface (1s) in the vertical direction (D11) of the first mold (1) is D1. The second bottom surface (213) of the second recess (21) is parallel to the second support surface (2s), and the height between the second bottom surface (213) and the uppermost end of the second protrusion (22) in the vertical direction (D21) of the second mold (2) is D2. The condition D1 > D2 is satisfied.

20. A self-piercing joining method using a mold kit according to any one of claims 1 to 19, characterized in that, The self-piercing engagement method is used to enable the first component (W1) to self-pierce and engage with the second component (W2).

21. The self-puncture joining method according to claim 20, characterized in that, The method includes: In the first joining step, the second component (W2) is placed on the first support surface (1s) of the first mold (1), the first component (W1) is pressed against the portion of the second component (W2) aligned with the first recess (11), and pressure is applied to the first component (W1) so that the first component (W1) pierces into the second component (W2) to form an intermediate assembly; and In the second joining step, the intermediate component is placed on the second support surface (2s) of the second mold (2), such that the joined portion of the first part (W1) and the second part (W2) in the intermediate component is located above the second recess (21), and pressure is applied to the first part (W1) so that the first part (W1) further penetrates into the second part (W2) to form a joining assembly.

22. The self-puncture joining method according to claim 20 or 21, characterized in that, The first component (W1) is made of a first material, and the second component (W2) is made of a second material. The first material and the second material are the same; or the first material and the second material have similar hardness.

23. A battery terminal contact assembly, characterized in that, Made using the mold kit of any one of claims 1 to 19 and / or the self-piercing joining method of any one of claims 20 to 22.

24. The battery terminal contact assembly according to claim 23, characterized in that, The battery terminal contact assembly includes: The pole post (101), which serves as the first component (W1); and The adapter plate (102), which serves as the second component (W2), is joined together with the pole post (101).

25. The battery terminal contact assembly according to claim 24, characterized in that, The pole (101) is made of a first material, and the adapter plate (102) is made of a second material. The hardness of the first material is the same as that of the second material; or the hardness of the first material is less than that of the second material.

26. The battery terminal contact assembly according to claim 25, characterized in that, The first material is aluminum, and the second material is copper; or Both the first material and the second material are copper; or Both the first material and the second material are aluminum.

27. The battery terminal contact assembly according to any one of claims 24 to 26, characterized in that, The pole post (101) includes: The first joint (1011) is formed in a hollow cylindrical shape and is joined together with the adapter piece (102); A flange (1012) is fixed to the first joint (1011); and The second joint (1013) is fixed to the flange (1012) and is located on the opposite side of the first joint (1011) relative to the flange (1012).

28. The battery terminal contact assembly according to claim 27, characterized in that, One end of the first joint (1011) is connected to the flange (1013), and the thickness of the other end of the first joint (1011) gradually decreases in the direction away from the flange, so that the other end of the first joint (1011) expands after it is engaged with the adapter piece (102).

29. The battery terminal contact assembly according to any one of claims 24 to 26, characterized in that, The portion of the adapter plate (102) used for engaging with the pole post (101) has a countersunk hole (1021c).

30. A battery, characterized in that, Includes the battery terminal contact assembly according to any one of claims 23 to 29.

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